Personal care articles comprising batting

ABSTRACT

The present invention relates to a substantially dry, disposable personal care article containing a substantially dry, disposable, multilayered personal care article suitable for cleansing, the article contains a water insoluble substrate containing a batting layer comprising a composite material; a nonwoven layer which is disposed adjacent to said batting layer; and a cleansing component disposed adjacent to said water insoluble substrate, wherein said component contains from about 10% to about 1000%, by weight of the water insoluble substrate, of a lathering surfactant. The present invention further relates to a substantially dry, disposable multilayered personal care article suitable for conditioning wherein the above-described article comprises a therapeutic benefit component, disposed adjacent to said water insoluble substrate, wherein said component comprises from about 10% to about 1000%, by weight of the water insoluble substrate, of a therapeutic benefit component in addition to or in lieu of the cleansing component.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation of application Ser. No.09/443,196, filed Nov. 19, 1999, and claims the benefit of U.S.provisional patent application Serial No. 60/146,746, filed on Aug. 2,1999 in the names of Smith et al.

TECHNICAL FIELD

[0002] The present invention relates to disposable, personal carearticles suitable for cleansing and/or therapeutically treating theskin, hair and any other sites in need of such treatment. These articleseach comprise a water insoluble substrate having a non-scouring, lofty,low-density batting layer comprising synthetic fibers and a non-lofty,fluid-permeable nonwoven layer disposed adjacent to the batting layer;and either a cleansing component disposed adjacent to the waterinsoluble substrate, wherein the cleansing component comprises fromabout 10% to about 1000%, by weight of the water insoluble substrate, ofa lathering surfactant or a therapeutic benefit component whichcomprises from about 10% to about 1000%, by weight of the waterinsoluble substrate, of a therapeutic benefit agent or both. Consumersuse the articles by wetting them with water and rubbing them on the areato be cleansed and/or therapeutically treated (e.g. conditioned).

[0003] The invention also encompasses methods for cleansing and/orconditioning the skin and hair using the articles of the presentinvention.

BACKGROUND OF THE INVENTION

[0004] Personal care products, particularly cleansing and conditioningproducts, have traditionally been marketed in a variety of forms such asbar soaps, creams, lotions, and gels. Typically, these products haveattempted to satisfy a number of criteria to be acceptable to consumers.These criteria include cleansing effectiveness, skin feel, mildness toskin, hair, and ocular mucosae, and lather volume. Ideal personalcleansers should gently cleanse the skin or hair, cause little or noirritation, and should not leave the skin or hair with a heavy buildupor overly dry when used frequently.

[0005] It is also highly desirable to deliver such cleansing andconditioning benefits from a disposable product. Disposable products areconvenient because they obviate the need to carry or store cumbersomebottles, bars, jars, tubes, and other forms of clutter includingcleansing products and other products capable of providing therapeuticor aesthetic benefits. Disposable products are also a more sanitaryalternative to the use of a sponge, washcloth, or other cleansingimplement intended for extensive reuse, because such implements candevelop bacterial growth, unpleasant odors, and other undesirablecharacteristics related to repeated use.

[0006] The articles of the present invention surprisingly provideeffective cleansing and/or therapeutic benefits to the skin and hair ina convenient, inexpensive, and sanitary manner. The present inventionprovides the convenience of not needing to carry, store, or use aseparate implement (such as a washcloth or sponge), a cleanser and/or atherapeutic benefit product. These articles are convenient to usebecause they are in the form of either a single, disposable personalcare article or multiple disposable articles useful for cleansing aswell as application of a therapeutic or aesthetic benefit agent.Moreover, these articles are suitable for use within or in conjunctionwith another personal care implement that is designed for more extensiveuse. In this instance, the articles of the present invention aredisposed within or attached to a separate personal care implement thatis not readily disposable, e.g., a bath towel or washcloth. In addition,the disposable articles of the present invention may be removeablyattached to a handle or grip suitable for moving the article over thesurface to be cleansed and/or therapeutically treated (e.g.,conditioned).

[0007] Although in preferred embodiments the articles of the presentinvention are suitable for personal care applications, they may also beuseful in a variety of other industries such as the automotive care,marine vehicle care, household care, animal care, etc. where surfaces orareas are in need of cleansing and/or application of a benefit agent,e.g., wax, conditioner, UV protectant, etc..

[0008] In preferred embodiments of the present invention, the articlesare suitable for personal care applications and are useful for cleansingand/or conditioning the skin, hair, and similar keratinous surfaces inneed of such treatment. Consumers use these articles by wetting themwith water and rubbing them on the area to be treated. The articleconsists of a water insoluble substrate having a non-scouring, lofty,low-density batting layer comprising synthetic fibers, a non-lofty,fluid-permeable nonwoven layer; and either a cleansing componentcontaining a lathering surfactant or a therapeutic benefit component orboth. Without being limited by theory, it is believed that the battinglayer of the substrate, particularly, enhances lathering (whereapplicable) which in turn increases cleansing and exfoliation, andoptimizes delivery and deposition of a therapeutic or aesthetic benefitagent that might be contained within the article.

SUMMARY OF THE INVENTION

[0009] The present invention relates to a substantially dry, disposablepersonal care article suitable for cleansing wherein the articlecomprises:

[0010] A substantially dry, disposable, multilayered personal carearticle suitable for cleansing, said article comprising:

[0011] a) a water insoluble substrate comprising:

[0012] 1) a batting layer comprising a composite material;

[0013] 2) a nonwoven layer which is disposed adjacent to said battinglayer; and

[0014] b) a cleansing component disposed adjacent to said waterinsoluble substrate, wherein said component comprises from about 10% toabout 1000%, by weight of the water insoluble substrate, of a latheringsurfactant.

[0015] The present invention further relates to a substantially dry,disposable multilayered personal care article suitable for conditioningwherein the article comprises:

[0016] a) a water insoluble substrate comprising:

[0017] 1) a batting layer comprising a composite material; and

[0018] 2) a nonwoven layer which is disposed adjacent to said battinglayer; and

[0019] b) a therapeutic benefit component, disposed adjacent to saidwater insoluble substrate, wherein said component comprises from about10% to about 1000%, by weight of the water insoluble substrate, of atherapeutic benefit agent .

[0020] In another embodiment, the present invention further relates to asubstantially dry, disposable multilayered personal care articlesuitable for cleansing and conditioning wherein the article comprises:

[0021] a) a water insoluble substrate comprising:

[0022] 1) a batting layer comprising a composite material; and

[0023] 2) a nonwoven layer which is disposed adjacent to said battinglayer;

[0024] b) a cleansing component disposed adjacent to said batting layer,wherein said component comprises from about 10% to about 1000%, byweight of the water insoluble substrate, of a lathering surfactant; and

[0025] c) a therapeutic benefit component, disposed adjacent to saidwater insoluble substrate, wherein said component comprises from about10% to about 1000%, by weight of the water insoluble substrate, of atherapeutic benefit agent.

[0026] In another embodiment, the present invention further relates to asubstantially dry, disposable, multilayered personal care articlesuitable for cleansing, said article comprising:

[0027] a) a water insoluble substrate comprising:

[0028] i) a batting layer comprising a composite material comprising anonwoven layer; and

[0029] b) a cleansing component disposed adjacent to said waterinsoluble substrate, wherein said component comprises from about 10% toabout 1000%, by weight of the water insoluble substrate, of a latheringsurfactant.

[0030] The present invention also relates to a method of cleansingand/or conditioning the skin and hair which comprises the steps of: a)wetting such articles with water and b) contacting the skin or hair withthe wetted articles.

[0031] All percentages and ratios used herein, unless otherwiseindicated, are by weight and all measurements made are at 25° C., unlessotherwise designated. The invention hereof can comprise, consist of, orconsist essentially of, the essential as well as optional ingredientsand components described therein.

[0032] In the description of the invention various embodiments and/orindividual features are disclosed. As will be apparent for the skilledpractitioner all combinations of such embodiments and features arepossible and can result in preferred executions of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0033] As used herein, “disposable” is used in its ordinary sense tomean an article that is disposed or discarded after a limited number ofusage events, preferably less than 25, more preferably less than about10, and most preferably less than about 2 entire usage events.

[0034] As used herein, “substantially dry” means that the articles ofthe present invention exhibit a Moisture Retention of less than about0.95 gms, preferably less than about 0.75 gms, even more preferably,less than about 0.5 gms, even more preferably less than about 0.25 gms,even still more preferably less than about 0.15 gms, and mostpreferably, less than about 0.1 gms. The determination of the MoistureRetention is discussed later.

[0035] The personal care articles of the present invention comprise thefollowing essential components.

[0036] Water Insoluble Substrate

[0037] The articles of the present invention comprise a water insolublesubstrate which further comprises at least two layers, namely anon-scouring, lofty, low-density batting layer and a non-lofty,fluid-permeable nonwoven layer. As used herein, “non-scouring” meansthat the layer exhibits an Abrasive Value of greater than about 15,preferably greater than about 30, more preferably greater than about 50,even more preferably greater than about 70, and most preferably greaterthan about 80 as determined by the Abrasiveness Value Methodologydescribed below. Preferably, the substrate layers are soft yetinvigorating to the skin of the consumer when used. In any case,however, the batting layer and the nonwoven layer are each defined ashaving both an interior and exterior surface. In both cases, theinterior surfaces of the layers are those which face the inside orinnermost portion of the article of the present invention whereas theexterior surfaces of the layers are those which face the outside oroutermost portion of the article. Generally, the orientation of thearticles of the present invention may be defined such that the nonwovenlayer is closer to the side of the article suitable for gripping (i.e.,the gripping side) while the batting layer is closer to the side of thearticle to be contacted with the area to be cleansed and/ortherapeutically treated, e.g. the skin/site contact side. Both sides ofthe article, however, are suitable for contact with the skin.

[0038] Without being limited by theory, the water insoluble substrateenhances cleansing and/or therapeutic treatment. The substrate can havethe same or differing textures on each side such that the gripping sideof the article is the same or a different texture as the skin/sitecontact side. The substrate may act as an efficient lathering andexfoliating implement. By physically coming into contact with the skinor hair, the substrate significantly aids in cleansing and removal ofdirt, makeup, dead skin, and other debris. In preferred embodiments,however, the substrate is non-scouring or nonabrasive to the skin.

[0039] Batting Layer

[0040] The batting layer of the present invention is lofty,non-scouring, and is of low-density. As used herein, “lofty” means thatthe layer has density of from about 0.00005 g/cm³ to about 0.1 g/cm³,preferably from about 0.001 g/cm³ to about 0.09 g/cm³ and a thickness offrom about 0.04 inches to about 2 inches at 5 gms/in². Also, as usedherein, “non-scouring” means having an Abrasiveness Value of greaterthan about 15, preferably greater than about 30, more preferably greatthan about 50, even more preferably greater than about 70, and mostpreferably greater than about 80, as defined by the Abrasiveness Valuedescribed below.

[0041] The batting layer preferably comprises synthetic materials. Asused herein, “synthetic” means that the materials are obtained primarilyfrom various man-made materials or from natural materials that have beenfurther altered. Suitable synthetic materials include, but are notlimited to, acetate fibers, acrylic fibers, cellulose ester fibers,modacrylic fibers, polyamide fibers, polyester fibers, polyolefinfibers, polyvinyl alcohol fibers, rayon fibers, polyethylene foam,polyurethane foam, and combinations thereof. Preferred syntheticmaterials, particularly fibers, may be selected from the groupconsisting of nylon fibers, rayon fibers, polyolefin fibers, polyesterfibers, and combinations thereof. Preferred polyolefin fibers are fibersselected from the group consisting of polyethylene, polypropylene,polybutylene, polypentene, and combinations and copolymers thereof. Morepreferred polyolefin fibers are fibers selected from the groupconsisting of polyethylene, polypropylene, and combinations andcopolymers thereof. Preferred polyester fibers are fibers selected fromthe group consisting of polyethylene terephthalate, polybutyleneterephthalate, polycyclohexylenedimethylene terephthalate, andcombinations and copolymers thereof. More preferred polyester fibers arefibers selected from the group consisting of polyethylene terephthalate,polybutylene terephthalate, and combinations and copolymers thereof.Most preferred synthetic fibers comprise solid staple polyester fibersthat comprise polyethylene terephthalate homopolymers. Suitablesynthetic materials may include solid single component (i.e., chemicallyhomogeneous) fibers, multiconstituent fibers (i.e., more than one typeof material making up each fiber), and multicomponent fibers (i.e.,synthetic fibers which comprise two or more distinct filament typeswhich are somehow intertwined to produce a larger fiber), andcombinations thereof., Preferred fibers include bicomponent fibers,multiconstituent fibers, and combinations thereof. Such bicomponentfibers may have a core-sheath configuration or a side-by-sideconfiguration. In either instance, the batting layer may comprise eithera combination of fibers comprising the above-listed materials or fiberswhich themselves comprise a combination of the above-listed materials.

[0042] For the core-sheath fibers, preferably, the cores comprisematerials selected from the group consisting of polyesters, polyolefinshaving a T_(g) of at least about 10° C. higher than the sheath material,and combinations thereof. Conversely, the sheaths of the bicomponentfibers preferably comprise materials selected from the group consistingof polyolefins having a T_(g) of at least about 10° C., lower than thecore material, polyesters polyolefins having a T_(g) of at least about10° C. lower than the core material, and combinations thereof.

[0043] In any instance, side-by side configuration, core-sheathconfiguration, or solid single component configuration, the fibers ofthe batting layer may exhibit a helical or spiral or crimpedconfiguration, particularly the bicomponent type fibers.

[0044] The batting layer may also comprise natural fibers. Suitablenatural fibers are described below in the Nonwoven Layer section.

[0045] Furthermore, the fibers of the batting layer preferably have anaverage thickness of from about 0.5 microns to about 150 microns. Morepreferably, the average thickness of the fibers are from about 5 micronsto about 75 microns. In an even more preferred embodiment, the averagethickness of the fibers are from about 8 microns to about 40 microns.Furthermore, the fibers of the batting layer may be of varying sizes,i.e., the fibers of the batting layer may comprise fibers havingdifferent average thicknesses. Also, the cross section of the fibers canbe round, flat, oval, elliptical or otherwise shaped.

[0046] In another embodiment, the batting layer of the present inventionmay comprise a composite material, i.e., a material having one or moreplies of the same or different suitable materials merely superimposedphysically, joined together continuously (e.g., laminated, etc.) or in adiscontinuous pattern, or by bonding at the external edges (orperiphery) of the layer and/or at discrete loci. For instance, thebatting layer may further comprise composite materials selected from thegroup consisting of fibrous nonwovens, sponges, foams, reticulatedfoams, polymeric nets, scrims, vacuum-formed laminates, formed films andformed film composite materials. It is preferred that the batting layercomprise a formed film composite material comprising at least one formedfilm and at least one nonwoven wherein the layer is vacuum formed. Asuitable formed film composite material includes, but is not limited to,a vacuum laminated composite formed film material formed by combining acarded polypropylene nonwoven having a basis weight of 30 gsm with aformed film.

[0047] Without being limited by theory, the batting layer is especiallyuseful as a skin contact side in the personal care article of thepresent invention due to its mild exfoliating properties. Furthermore,the preferred synthetic fibers which make up the batting layer arelargely hydrophobic thus allowing water to readily flow through thearticle to reach the cleansing component and readily flow out from thearticle to produce a high volume of flash lather which tapers off duringuse but which still suffices through an entire showering or bathingexperience.

[0048] Abrasiveness Value Methodology

[0049] The Abrasiveness Value indicates the “non-scouring” property ofthe batting layers of the present articles. The batting layers of thepresent invention are mildly exfoliating but are not rough to the skin.Therefore, the Abrasiveness Value determination involves rubbing thesubstrate along a test surface using a mechanical device and thenexamining the resulting scratch marks produced on the test surface usingdifferent analysis techniques.

[0050] The following equipment is needed for the methodology.

[0051] 1. Martindale Toothbrush Wear and Abrasion Tester: Model 103,serial nos. 103-1386/2 upwards. Martindale 07-01-88 made by James H.Heal and Co. Ltd. Textile Testing and QC Equipment. Foot area: 43×44 mm.1 Kg weight.

[0052] 2. Capped Polystyrene strips 11×8 cm. Clear general purposepolystyrene layer on white High Impact Polystyrene, e.g., EMA ModelSupplies SS-20201L.

[0053] 3. Substrates to be tested.

[0054] 4. Glossmeter, e.g. Sheen Tri-Microgloss 20-60-85

[0055] Prepare the polystyrene strips for scratching by removing plasticprotective coating from the side to be scratched and rinsing withethanol (do not use tissue). Place the strip onto a non-abrasive surfaceand allow strip to dry in the air. Then, attach the polystyrene strip tothe base of a Martindale wear tester with tape along the edges. Alignthe strip centrally under the path of the scrubbing device, with thelength of the strip in the direction of movement. Cut a 2.5″×2.5″substrate sample. Attach the substrate sample to the scrubbing foot ofthe Martindale wear tester, with double sided tape, aligning the machinedirection of the substrate with the direction of travel. Secure thescrubbing foot assembly into the instrument with the screws supplied.Slot 1 Kg weight on to the top of the scrubbing foot assembly and ensurethe scrubbing foot moves only in one direction (forward and backwards).Cover the entire Martindale wear tester with a safety screen. Set themachine to perform 50 cycles in 1 minute and allow to run.(Frequency=0.833 Hz). Once the machine has stopped take off the footerassembly and lift the polystyrene strip off the base of the machine.Label the polystyrene indicating the substrate used and store in aplastic bag.

[0056] Next, the strips are analyzed. The strips are placed on a blackconstruction paper background and at least 5 samples of the samesubstrate are analyzed to get a reproducible average. The Glossmeter isplaced orthogonally (such that light beam is at right angles toscratches) and centrally over the scratched side of the polystyrenestrip. A 20° angle is selected and the sample is measured yielding theAbrasiveness Value. As the Abrasiveness Value decreases the scratchinessor scouring property of a substrate increases.

[0057] Nonwoven Layer

[0058] The water insoluble substrate of the present invention furthercomprises a nonwoven layer attached to the batting layer. This nonwovenlayer is preferably non-lofty and fluid-permeable. As used herein,“non-lofty” means having a thickness of from about 0.001 to about 0.05inches. This nonwoven layer is useful for engaging or retaining thecleansing component and/or therapeutic benefit component within thearticle. Furthermore, the nonwoven layer may also be suitable forcontact with the skin in which case it is preferred that the layer issoft to the skin.

[0059] Materials suitable for the nonwoven layer are selected from thegroup consisting of cellulosic nonwovens, non-lofty nonwovens, sponges(i.e., both natural and synthetic), formed films, non-lofty battings,and combinations thereof. Preferably, the nonwoven layer comprisesmaterials selected from the group consisting of cellulosic nonwovens,non-lofty nonwovens, formed films, non-lofty battings, foams, sponges,reticulated foams, vacuum-formed laminates, scrims, polymeric nets, andcombinations thereof. More preferably, the nonwoven layer comprisesmaterials selected from the group consisting of cellulosic nonwovens,non-lofty nonwovens, formed films, non-lofty battings, and combinationsthereof. As used herein, “nonwoven” means that the layer does notcomprise fibers which are woven into a fabric but the layer need notcomprise fibers at all, e.g., formed films, sponges, foams, scrims,etc.. When the layer comprises fiber, the fibers can either be random(i.e., randomly aligned) or they can be carded (i.e., combed to beoriented in primarily one direction). Furthermore, the nonwoven layercan be a composite material composed of a combination of additionallayers, i.e., plies, of random and carded fibers.

[0060] In a preferred embodiment, the nonwoven layer is apertured. Theapertures in the nonwoven layer of the water insoluble substrate willgenerally range in average diameter between about 0.5 mm and 5 mm. Morepreferably, the apertures will range in size between about 1 mm to 4 mmin average diameter. Preferably, no more than about 10% of the aperturesin the nonwoven layer of the substrate will fall outside these sizeranges. More preferably, no more than about 5% of the apertures in thenonwoven layer will fall outside these size ranges. For apertures whichare not circular in shape, the “diameter” of the aperture refers to thediameter of a circular opening having the same surface area as theopening of the non-circular shaped aperture.

[0061] Within the nonwoven layer, the apertures will generally occur ata frequency of from about 0.5 to 12 apertures per straight linearcentimeter. More preferably, the apertures in the surface of the layerwill occur at a frequency of from about 1.5 to 6 apertures per straightlinear centimeter.

[0062] The apertures must at least be placed within the nonwoven layer.Such apertures need not protrude completely through one surface of thenonwoven layer to the other. They, however, may do so. Additionally,apertures may or may not be placed in the batting layer of the substratesuch that the article is apertured through it's entire volume.

[0063] Apertures may be formed in the nonwoven layer of the waterinsoluble substrate as such a substrate, or layer thereof, is beingformed or fabricated. Alternatively, apertures may be formed in thenonwoven layer after the substrate comprising the layer has beencompletely formed.

[0064] The nonwoven layer may comprise a variety of both natural andsynthetic fibers or materials. As used herein, “natural” means that thematerials are derived from plants, animals, insects or byproducts ofplants, animals, and insects. The conventional base starting material isusually a fibrous web comprising any of the common synthetic or naturaltextile-length fibers, or combinations thereof.

[0065] Nonlimiting examples of natural materials useful in the presentinvention include, but are not limited to, silk fibers, keratin fibersand cellulosic fibers. Nonlimiting examples of keratin fibers includethose selected from the group consisting of wool fibers, camel hairfibers, and the like. Nonlimiting examples of cellulosic fibers includethose selected from the group consisting of wood pulp fibers, cottonfibers, hemp fibers, jute fibers, flax fibers, and combinations thereof.Cellulosic fiber materials are preferred in the present invention.

[0066] Nonlimiting examples of synthetic materials useful in the presentinvention include those selected from the group consisting of acetatefibers, acrylic fibers, cellulose ester fibers, modacrylic fibers,polyamide fibers, polyester fibers, polyolefin fibers, polyvinyl alcoholfibers, rayon fibers, polyethylene foam, polyurethane foam, andcombinations thereof. Examples of suitable synthetic materials includeacrylics such as acrilan, creslan, and the acrylonitrile-based fiber,orlon; cellulose ester fibers such as cellulose acetate, arnel, andacele; polyamides such as nylons (e.g., nylon 6, nylon 66, nylon 610,and the like); polyesters such as fortrel, kodel, and the polyethyleneterephthalate fiber, polybutylene terephalate fiber, dacron; polyolefinssuch as polypropylene, polyethylene; polyvinyl acetate fibers;polyurethane foams and combinations thereof. These and other suitablefibers and the nonwovens prepared therefrom are generally described inRiedel, “Nonwoven Bonding Methods and Materials,” Nonwoven World (1987);The Encyclopedia Americana, vol. 11, pp. 147-153, and vol. 26, pp.566-581 (1984); U.S. Pat. No. 4,891,227, to Thaman et al., issued Jan.2, 1990; and U.S. Pat. No. 4,891,228, each of which is incorporated byreference herein in its entirety. Additionally, any synthetic materialsmentioned above as suitable for inclusion in the batting layer may alsobe included in the nonwoven layer.

[0067] Nonwovens made from natural materials consist of webs or sheetsmost commonly formed on a fine wire screen from a liquid suspension ofthe fibers. See C. A. Hampel et al., The Encyclopedia of Chemistry,third edition, 1973, pp. 793-795 (1973); The Encyclopedia Americana,vol. 21, pp. 376-383 (1984); and G. A. Smook, Handbook of Pulp and PaperTechnologies, Technical Association for the Pulp and Paper Industry(1986); which are incorporated by reference herein in their entirety.

[0068] Natural material nonwovens useful in the present invention may beobtained from a wide variety of commercial sources. Nonlimiting examplesof suitable commercially available paper layers useful herein includeAirtex®, an embossed airlaid cellulosic layer having a base weight ofabout 71 gsy, available from James River, Green Bay, Wis.; andWalkisoft®, an embossed airlaid cellulosic having a base weight of about75 gsy, available from Walkisoft U.S.A., Mount Holly, N.C.

[0069] Additional suitable nonwoven materials include, but are notlimited to, those disclosed in U.S. Pat. No. 4,447,294, issued to Osbornon May 8, 1984; U.S. Pat. No. 4,603,176 issued to Bjorkquist on Jul. 29,1986; U.S. Pat. No. 4,981,557 issued to Bjorkquist on Jan. 1, 1991; U.S.Pat. No. 5,085,736 issued to Bjorkquist on Feb. 4, 1992; U.S. Pat. No.5,138,002 issued to Bjorkquist on Aug. 8, 1992; U.S. Pat. No. 5,262,007issued to Phan et al. on Nov. 16, 1993; U.S. Pat. No. 5,264,082, issuedto Phan et al. on Nov. 23, 1993; U.S. Pat. No. 4,637,859 issued toTrokhan on Jan. 20, 1987; U.S. Pat. No. 4,529,480 issued to Trokhan onJul. 16, 1985; U.S. Pat. No. 4,687,153 issued to McNeil on Aug. 18,1987; U.S. Pat. No. 5,223,096 issued to Phan et al. on Jun. 29, 1993 andU.S. Pat. No. 5,679,222, issued to Rasch et al. on Oct. 21, 1997, eachof which is incorporated by reference herein in its entirety.

[0070] Methods of making nonwovens are well known in the art. Generally,these nonwovens can be made by air-laying, water-laying, meltblowing,coforming, spunbonding, or carding processes in which the fibers orfilaments are first cut to desired lengths from long strands, passedinto a water or air stream, and then deposited onto a screen throughwhich the fiber-laden air or water is passed. The resulting layer,regardless of its method of production or composition, is then subjectedto at least one of several types of bonding operations to anchor theindividual fibers together to form a self-sustaining web. In the presentinvention the nonwoven layer can be prepared by a variety of processesincluding, but not limited to, air-entanglement, hydroentanglement,thermal bonding, and combinations of these processes.

[0071] Nonwovens made from synthetic materials useful in the presentinvention can be obtained from a wide variety of commercial sources.Nonlimiting examples of suitable nonwoven layer materials useful hereininclude HEF 40-047, an apertured hydroentangled material containingabout 50% rayon and 50% polyester, and having a basis weight of about 61grams per square meter (gsm), available from Veratec, Inc., Walpole,Mass.; HEF 140-102, an apertured hydroentangled material containingabout 50% rayon and 50% polyester, and having a basis weight of about 67gsm, available from Veratec, Inc., Walpole, Mass.; Novonet® 149-616, athermo-bonded grid patterned material containing about 100%polypropylene, and having a basis weight of about 60 gsm available fromVeratec, Inc., Walpole, Mass.; Novonet® 149-801, a thermo-bonded gridpatterned material containing about 69% rayon, about 25% polypropylene,and about 6% cotton, and having a basis weight of about 90 gsm,available from Veratec, Inc. Walpole, Mass.; Novonet® 149-191, athermo-bonded grid patterned material containing about 69% rayon, about25% polypropylene, and about 6% cotton, and having a basis weight ofabout 120 gsm, available from Veratec, Inc. Walpole, Mass.; HEF Nubtex®149-801, a nubbed, apertured hydroentangled material, containing about100% polyester, and having a basis weight of about 84 gsm, availablefrom Veratec, Inc. Walpole, Mass.; Keybak® 951V, a dry formed aperturedmaterial, containing about 75% rayon, about 25% acrylic fibers, andhaving a basis weight of about 51 gsm, available from Chicopee, NewBrunswick, N.J.; Keybak® 1368, an apertured material, containing about75% rayon, about 25% polyester, and having a basis weight of about 47gsm, available from Chicopee, New Brunswick, N.J.; Duralace® 1236, anapertured, hydroentangled material, containing about 100% rayon, andhaving a basis weight from about 48 gsm to about 138 gsm, available fromChicopee, New Brunswick, N.J.; Duralace® 5904, an apertured,hydroentangled material, containing about 100% polyester, and having abasis weight from about 48 gsm to about 138 gsm, available fromChicopee, New Brunswick, N.J.; Chicopee® 5763, a carded hydroaperturedmaterial (8×6 apertures per inch, 3×2 apertures per cm), containingabout 70% rayon, about 30% polyester, and a optionally a latex binder(Acrylate or EVA based) of up to about 5% w/w, and having a basis weightfrom about 60 gsm to about 90 gsm, available form Chicopee, NewBrunswick, N.J.; Chicopee® 9900 series (e.g., Chicopee 9931, 62 gsm,50/50 rayon/polyester, and Chicopee 9950 50 gsm, 50/50 rayon/polyester),a carded, hydroentangled material, containing a fiber composition offrom 50% rayon/50% polyester to 0% rayon/100% polyester or 100% rayon/0%polyester, and having a basis weight of from about 36 gsm to about 84gsm, available form Chicopee, New Brunswick, N.J.; Sontara 8868, ahydroentangled material, containing about 50% cellulose and about 50%nolyester, and having a basis weight of about 72 gsm, available fromDupont Chemical Corp. Preferred non-woven substrate materials have abasis weight of about from 24 gsm to about 96 gsm, more preferably fromabout 36 gsm to about 84 gsm, and most preferably from about 42 gsm toabout 78 gsm.

[0072] The nonwoven layer may also be a polymeric mesh sponge asdescribed in European Patent Application No. EP 702550A1 published Mar.27, 1996, which is incorporated by reference herein in its entirety.Such polymeric mesh sponges comprise a plurality of plies of an extrudedtubular netting mesh prepared from nylon or a strong flexible polymer,such as addition polymers of olefin monomers and polyamides ofpolycarboxylic acids.

[0073] The nonwoven layer may also comprise formed films and compositematerials, i.e., multiple materials containing formed films. Preferably,such formed films comprise plastics which tend to be soft to the skin.Suitable soft plastic formed films include, but are not limited to,polyolefins such as low density polyethylenes (LDPE). In such caseswhere the nonwoven layer comprises a plastic formed film, it ispreferred that the nonwoven layer be apertured, e.g., macroapertured ormicroapertured, such that the layer is fluid permeable. In oneembodiment, the nonwoven layer comprises a plastic formed film which isonly microapertured. The surface aberrations of the microapertures,i.e., the male side, are preferably located on the interior surface ofthe second layer and preferably face toward the inside of the substrate,i.e., toward the cleansing component and/or therapeutic benefitcomponent. In certain embodiments which include apertures havingpetal-like edged surface aberrations, without being limited by theory,it is believed that when the surface aberrations of the apertures facetoward the surfactant-containing cleansing component and/or therapeuticbenefit component, the application of pressure by the hand to thearticle allows the petal-like edges of the surface aberrations to foldinward thereby creating numerous valves on the interior surface of thelayer which in effect meter out the cleansing component and/ortherapeutic benefit component contained within the article therebyextending the article's useful life.

[0074] In another embodiment, the nonwoven layer comprises a plasticformed film which is both microapertured and macroapertured. In suchembodiments, the nonwoven layer is well-suited to contact the area to becleansed and/or therapeutically treated given the cloth-like feel ofsuch microapertured films. Preferably, in such an embodiment, thesurface aberrations of the microapertures face opposite of the surfaceaberrations of the macroapertures on the nonwoven layer. In such aninstance, it is believed that the macroapertures maximize the overallwetting/lathering of the article by the three-dimensional thicknessformed from the surface aberrations which are under constant compressionand decompression during the use of the article thereby creatinglathering bellows.

[0075] In any case, the nonwoven layer comprising a formed filmpreferably has at least about 100 apertures/cm², more preferably atleast 500 apertures/cm², even still more preferably at least about 1000apertures/cm², and most preferably at least about 1500 apertures/cm² ofthe substrate. More preferred embodiments of the present inventioninclude a nonwoven layer which has water flux rate of from about 5cm³/cm²-s to about 70 cm³/cm²-s, more preferably from about 10 cm³/cm²-sto about 50 cm³/cm²-s and most preferably from about 15 cm³/cm²-s toabout 40 cm³/cm²-s.

[0076] Suitable formed films and formed film-containing compositematerials useful in the nonwoven layer of the present invention include,but are not limited to, those disclosed in U.S. Pat. No. 4,342,314issued to Radel et al. on Aug. 3, 1982, commonly assigned co-pendingapplication U.S. Ser. No. 08/326,571 and PCT Application No. US95/07435,filed Jun. 12, 1995 and published Jan. 11, 1996, and U.S. Pat. No.4,629,643, issued to Curro et al. on Dec. 16, 1986, each of which isincorporated by reference herein in its entirety. Furthermore, thenonwoven layer may be a formed film composite material comprising atleast one formed film and at least one nonwoven wherein the layer isvacuum formed. A suitable formed film composite material includes, butis not limited to, a vacuum laminated composite formed film materialformed by combining a carded polypropylene nonwoven having a basisweight of 30 gsm with a formed film.

[0077] Additionally, the nonwoven layer and the aforementioned battinglayer are preferably bonded to one another in order to maintain theintegrity of the article. This bonding may consist of spot bonding(e.g., hot point bonding), continuous joining (e.g., laminated, etc.) ina discontinuous pattern, or by bonding at the external edges (orperiphery) of the layers and/or at discrete loci or combinationsthereof. When spot bonding is used in the present articles, it ispreferred that the spot bonds are separated by a distance of not lessthan about 1 cm. In any instance, however, the bonding may be arrangedsuch that geometric shapes and patterns, e.g. diamonds, circles,squares, etc., are created on the exterior surfaces of the layers andthe resulting article.

[0078] It is also envisioned in the articles of the present inventionthat the first layer and any additional layers may be surface modifiedto form single composite layer having 2 sides with different textures.Thus, in effect, the water insoluble substrate can be construed ascomprising a single composite layer with dual textured sides orsurfaces.

[0079] In any event, it is preferred that the bonded area presentbetween the batting and any additional layers (including the nonwovenlayers) be not greater than about 50% of the total surface area of thelayers, preferably not greater than about 15%, more preferably notgreater than about 10%, and most preferably not greater than about 8%.

[0080] Each of the layers discussed herein comprises at least twosurfaces, namely an interior surface and an exterior surface, each ofwhich may have the same or different texture and abrasiveness.Preferably, the articles of the present invention comprise substratesand therefore layers which are soft to the skin. However, differingtexture substrates can result from the use of different combinations ofmaterials or from the use of different manufacturing processes or acombination thereof. For instance, a dual textured water insolublesubstrate can be made to provide a personal care article with theadvantage of having a more abrasive side for exfoliation and a softer,absorbent side for gentle cleansing and/or therapeutic treatment. Inaddition, the separate layers of the substrate can be manufactured tohave different colors, thereby helping the user to further distinguishthe surfaces.

[0081] Furthermore, each of the layers of the articles as well as thearticles themselves may be made into a wide variety of shapes and formsincluding flat pads, thick pads, thin sheets, ball-shaped implements,irregularly shaped implements. The exact size of the layers will dependupon the desired use and characteristics of the article and may range insurface area size from about a square inch to about hundreds of squareinches. Especially convenient layer and article shapes include, but arenot limited to, square, circular, rectangular, hourglass, mitt-type oroval shapes having a surface area of from about 5 in² to about 200 in²,preferably from about 6 in² to about 120 in², and more preferably fromabout 15 in² to about 100 in², and a thickness of from about 0.5 mm toabout 50 mm, preferably from about 1 mm to about 25 mm, and morepreferably from about 2 mm to about 20 mm.

[0082] Cleaning Component

[0083] The articles of the present invention comprise a cleansingcomponent, which further comprises one or more surfactants. Thecleansing component is disposed adjacent to the water insolublesubstrate. In certain embodiments, the cleansing component isimpregnated into the water insoluble substrate. In another embodiment,the cleansing component is deposited onto either or both surfaces of thewater insoluble substrate. The articles of the present inventioncomprise from about 10% to about 1,000%, preferably from about 50% toabout 600%, and more preferably from about 100% to about 250%, based onthe weight of the water insoluble substrate, of the surfactant. Also,the articles of the present invention preferably comprise at least about1 gram, by weight of the water insoluble substrate, of a surfactant.Thus, the cleansing component may be added to the substrate withoutrequiring a drying process.

[0084] The surfactants of the cleansing component are preferablylathering surfactants. As used herein, “lathering surfactant” means asurfactant, which when combined with water and mechanically agitatedgenerates a foam or lather. Such surfactants are preferred sinceincreased lather is important to consumers as an indication of cleansingeffectiveness. In certain embodiments, the surfactants or combinationsof surfactants are mild. As used herein, “mild” means that thesurfactants as well as to the articles of the present inventiondemonstrate skin mildness at least milder than common bar soap matriceswhich typically comprise a combination of natural soap and syntheticsurfactant (e.g., Lever 2000 and Zest®). Methods for measuring mildness,or inversely the irritancy, of surfactant containing articles, are basedon a skin barrier destruction test. In this test, the milder thesurfactant, the lesser the skin barrier is destroyed. Skin barrierdestruction is measured by the relative amount of radio-labeled (tritiumlabeled) water (3H—H₂O) which passes from the test solution through theskin epidermis into the physiological buffer contained in the diffusatechamber. This test is described by T. J. Franz in the J. Invest.Dermatol., 1975, 64, pp. 190-195; and in U.S. Pat. No. 4,673,525, toSmall et al., issued Jun. 16, 1987, which are both incorporated byreference herein in their entirety. Other testing methodologies fordetermining surfactant mildness well known to one skilled in the art canalso be used.

[0085] A wide variety of lathering surfactants are useful herein andinclude those selected from the group consisting of anionic latheringsurfactants, nonionic lathering surfactants, cationic latheringsurfactants, amphoteric lathering surfactants, and mixtures thereof.

[0086] Anionic Lathering Surfactants

[0087] Nonlimiting examples of anionic lathering surfactants useful inthe compositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byAllured Publishing Corporation; McCutcheon's, Functional Materials,North American Edition (1992); and U.S. Pat. No. 3,929,678, to Laughlinet al., issued Dec. 30, 1975, each of which is incorporated by referenceherein in their entirety.

[0088] A wide variety of anionic surfactants are potentially usefulherein. Nonlimiting examples of anionic lathering surfactants includethose selected from the group consisting of alkyl and alkyl ethersulfates, sulfated monoglycerides, sulfonated olefins, alkyl arylsulfonates, primary or secondary alkane sulfonates, alkylsulfosuccinates, acyl taurates, acyl isethionates, alkyl glycerylethersulfonate, sulfonated methyl esters, sulfonated fatty acids, alkylphosphates, acyl glutamates, acyl sarcosinates, alkyl sulfoacetates,acylated peptides, alkyl ether carboxylates, acyl lactylates, anionicfluorosurfactants, and combinations thereof. Combinations of anionicsurfactants can be used effectively in the present invention.

[0089] Anionic surfactants for use in the cleansing component includealkyl and alkyl ether sulfates. These materials have the respectiveformulae R1O—SO3M and R1(CH2H4O)x-O—SO3M, wherein R1 is a saturated orunsaturated, branched or unbranched alkyl group from about 8 to about 24carbon atoms, x is 1 to 10, and M is a water-soluble cation such asammonium, sodium, potassium, magnesium, triethanolamine, diethanolamineand monoethanolamine. The alkyl sulfates are typically made by thesulfation of monohydric alcohols (having from about 8 to about 24 carbonatoms) using sulfur trioxide or other known sulfation technique. Thealkyl ether sulfates are typically made as condensation products ofethylene oxide and monohydric alcohols (having from about 8 to about 24carbon atoms) and then sulfated. These alcohols can be derived fromfats, e.g., coconut oil or tallow, or can be synthetic. Specificexamples of alkyl sulfates which may be used in the cleansing componentare sodium, ammonium, potassium, magnesium, or TEA salts of lauryl ormyristyl sulfate. Examples of alkyl ether sulfates which may be usedinclude ammonium, sodium, magnesium, or TEA laureth-3 sulfate.

[0090] Another suitable class of anionic surfactants are the sulfatedmonoglycerides of the form R1CO—O—CH2—C(OH)H—CH2—O—SO3M, wherein R1 is asaturated or unsaturated, branched or unbranched alkyl group from about8 to about 24 carbon atoms, and M is a water-soluble cation such asammonium, sodium, potassium, magnesium, triethanolamine, diethanolamineand monoethanolamine. These are typically made by the reaction ofglycerin with fatty acids (having from about 8 to about 24 carbon atoms)to form a monoglyceride and the subsequent sulfation of thismonoglyceride with sulfur trioxide. An example of a sulfatedmonoglyceride is sodium cocomonoglyceride sulfate.

[0091] Other suitable anionic surfactants include olefin sulfonates ofthe form R1SO3M, wherein R1 is a mono-olefin having from about 12 toabout 24 carbon atoms, and M is a water-soluble cation such as ammonium,sodium, potassium, magnesium, triethanolamine, diethanolamine andmonoethanolamine. These compounds can be produced by the sulfonation ofalpha olefins by means of uncomplexed sulfur trioxide, followed byneutralization of the acid reaction mixture in conditions such that anysultones which have been formed in the reaction are hydrolyzed to givethe corresponding hydroxyalkanesulfonate. An example of a sulfonatedolefin is sodium C14/C16 alpha olefin sulfonate.

[0092] Other suitable anionic surfactants are the linear alkylbenzenesulfonates of the form R1—C6H4—SO3M, wherein R1 is a saturated orunsaturated, branched or unbranched alkyl group from about 8 to about 24carbon atoms, and M is a water-soluble cation such as ammonium, sodium,potassium, magnesium, triethanolamine, diethanolamine andmonoethanolamine. These are formed by the sulfonation of linear alkylbenzene with sulfur trioxide. An example of this anionic surfactant issodium dodecylbenzene sulfonate.

[0093] Still other anionic surfactants suitable for this cleansingcomponent include the primary or secondary alkane sulfonates of the formR1SO3M, wherein R1 is a saturated or unsaturated, branched or unbranchedalkyl chain from about 8 to about 24 carbon atoms, and M is awater-soluble cation such as ammonium, sodium, potassium, magnesium,triethanolamine, diethanolamine and monoethanolamine. These are commonlyformed by the sulfonation of paraffins using sulfur dioxide in thepresence of chlorine and ultraviolet light or another known sulfonationmethod. The sulfonation can occur in either the secondary or primarypositions of the alkyl chain. An example of an alkane sulfonate usefulherein is alkali metal or ammonium C13-C17 paraffin sulfonates.

[0094] Still other suitable anionic surfactants are the alkylsulfosuccinates, which include disodium N-octadecylsulfosuccinamate;diammonium lauryl sulfosuccinate; tetrasodiumN-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinate; diamyl ester of sodiumsulfosuccinic acid; dihexyl ester of sodium sulfosuccinic acid; anddioctyl esters of sodium sulfosuccinic acid.

[0095] Also useful are taurates which are based on taurine, which isalso known as 2-aminoethanesulfonic acid. Examples of taurates includeN-alkyltaurines such as the one prepared by reacting dodecylamine withsodium isethionate as detailed in U.S. Pat. No. 2,658,072 which isincorporated herein by reference in its entirety. Other examples basedof taurine include the acyl taurines formed by the reaction of n-methyltaurine with fatty acids (having from about 8 to about 24 carbon atoms).

[0096] Another class of anionic surfactants suitable for use in thecleansing component is the acyl isethionates. The acyl isethionatestypically have the formula R1CO—O—CH2CH2SO3M wherein R1 is a saturatedor unsaturated, branched or unbranched alkyl group having from about 10to about 30 carbon atoms, and M is a cation. These are typically formedby the reaction of fatty acids (having from about 8 to about 30 carbonatoms) with an alkali metal isethionate. Nonlimiting examples of theseacyl isethionates include ammonium cocoyl isethionate, sodium cocoylisethionate, sodium lauroyl isethionate, and mixtures thereof.

[0097] Still other suitable anionic surfactants are the alkylglycerylether sulfonates of the form R1—OCH2—C(OH)H—CH2—SO3M, wherein R1 is asaturated or unsaturated, branched or unbranched alkyl group from about8 to about 24 carbon atoms, and M is a water-soluble cation such asammonium, sodium, potassium, magnesium, triethanolamine, diethanolamineand monoethanolamine. These can be formed by the reaction ofepichlorohydrin and sodium bisulfite with fatty alcohols (having fromabout 8 to about 24 carbon atoms) or other known methods. One example issodium cocoglyceryl ether sulfonate.

[0098] Other suitable anionic surfactants include the sulfonated fattyacids of the form R1—CH(SO4)—COOH and sulfonated methyl esters of thefrom R1—CH(SO4)—CO—O—CH3, where R1 is a saturated or unsaturated,branched or unbranched alkyl group from about 8 to about 24 carbonatoms. These can be formed by the sulfonation of fatty acids or alkylmethyl esters (having from about 8 to about 24 carbon atoms) with sulfurtrioxide or by another known sulfonation technique. Examples includealpha sulphonated coconut fatty acid and lauryl methyl ester.

[0099] Other anionic materials include phosphates such as monoalkyl,dialkyl, and trialkylphosphate salts formed by the reaction ofphosphorous pentoxide with monohydric branched or unbranched alcoholshaving from about 8 to about 24 carbon atoms. These could also be formedby other known phosphation methods. An example from this class ofsurfactants is sodium mono or dilaurylphosphate.

[0100] Other anionic materials include acyl glutamates corresponding tothe formula R1CO—N(COOH)—CH2CH2—CO2M wherein R1 is a saturated orunsaturated, branched or unbranched alkyl or alkenyl group of about 8 toabout 24 carbon atoms, and M is a water-soluble cation. Nonlimitingexamples of which include sodium lauroyl glutamate and sodium cocoylglutamate.

[0101] Other anionic materials include alkanoyl sarcosinatescorresponding to the formula R1CON(CH3)—CH2CH2—CO2M wherein R1 is asaturated or unsaturated, branched or unbranched alkyl or alkenyl groupof about 10 to about 20 carbon atoms, and M is a water-soluble cation.Nonlimiting examples of which include sodium lauroyl sarcosinate, sodiumcocoyl sarcosinate, and ammonium lauroyl sarcosinate.

[0102] Other anionic materials include alkyl ether carboxylatescorresponding to the formula R1—(OCH2CH2)x-OCH2—CO2M wherein R1 is asaturated or unsaturated, branched or unbranched alkyl or alkenyl groupof about 8 to about 24 carbon atoms, x is 1 to 10, and M is awater-soluble cation. Nonlimiting examples of which include sodiumlaureth carboxylate.

[0103] Other anionic materials include acyl lactylates corresponding tothe formula R1CO—[O—CH(CH3)—CO]x-CO2M wherein R1 is a saturated orunsaturated, branched or unbranched alkyl or alkenyl group of about 8 toabout 24 carbon atoms, x is 3, and M is a water-soluble cation.Nonlimiting examples of which include sodium cocoyl lactylate.

[0104] Other anionic materials include the carboxylates, nonlimitingexamples of which include sodium lauroyl carboxylate, sodium cocoylcarboxylate, and ammonium lauroyl carboxylate. Anionic flourosurfactantscan also be used.

[0105] Other anionic materials include natural soaps derived from thesaponification of vegetable and/or animal fats & oils exmaples of whichinclude sodium laurate, sodium myristate, palmitate, stearate,tallowate, cocoate.

[0106] Any counter cation, M, can be used on the anionic surfactant.Preferably, the counter cation is selected from the group consisting ofsodium, potassium, ammonium, monoethanolamine, diethanolamine, andtriethanolamine. More preferably, the counter cation is ammonium.

[0107] Nonionic Lathering Surfactants

[0108] Nonlimiting examples of nonionic lathering surfactants for use inthe compositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; and McCutcheon's, Functional Materials,North American Edition (1992); both of which are incorporated byreference herein in their entirety.

[0109] Nonionic lathering surfactants useful herein include thoseselected from the group consisting of alkyl glucosides, alkylpolyglucosides, polyhydroxy fatty acid amides, alkoxylated fatty acidesters, sucrose esters, amine oxides, and mixtures thereof.

[0110] Alkyl glucosides and alkyl polyglucosides are useful herein, andcan be broadly defined as condensation products of long chain alcohols,e.g., C8-30 alcohols, with sugars or starches or sugar or starchpolymers, i.e., glycosides or polyglycosides. These compounds can berepresented by the formula (S)_(n)—O—R wherein S is a sugar moiety suchas glucose, fructose, mannose, and galactose; n is an integer of fromabout 1 to about 1000, and R is a C8-30 alkyl group. Examples of longchain alcohols from which the alkyl group can be derived include decylalcohol, cetyl alcohol, stearyl alcohol, lauryl alcohol, myristylalcohol, oleyl alcohol, and the like. Preferred examples of thesesurfactants include those wherein S is a glucose moiety, R is a C8-20alkyl group, and n is an integer of from about 1 to about 9.Commercially available examples of these surfactants include decylpolyglucoside (available as APG 325 CS from Henkel) and laurylpolyglucoside (available as APG 600CS and 625 CS from Henkel). Alsouseful are sucrose ester surfactants such as sucrose cocoate and sucroselaurate.

[0111] Other useful nonionic surfactants include polyhydroxy fatty acidamide surfactants, more specific examples of which include glucosamides,corresponding to the structural formula:

[0112] wherein: R¹ is H, C₁-C₄ alkyl, 2-hydroxyethyl, 2-hydroxy-propyl,preferably C₁-C₄ alkyl, more preferably methyl or ethyl, most preferablymethyl; R² is C₅-C₃₁ alkyl or alkenyl, preferably C₇-C₁₉ alkyl oralkenyl, more preferably C₉-C ₁₇ alkyl or alkenyl, most preferablyC₁₁-C₁₅ alkyl or alkenyl; and Z is a polhydroxyhydrocarbyl moiety havinga linear hydrocarbyl chain with a least 3 hydroxyls directly connectedto the chain, or an alkoxylated derivative (preferably ethoxylated orpropoxylated) thereof. Z preferably is a sugar moiety selected from thegroup consisting of glucose, fructose, maltose, lactose, galactose,mannose, xylose, and mixtures thereof. An especially preferredsurfactant corresponding to the above structure is coconut alkylN-methyl glucoside amide (i.e., wherein the R²CO— moiety is derived fromcoconut oil fatty acids). Processes for making compositions containingpolyhydroxy fatty acid amides are disclosed, for example, in G.B. PatentSpecification 809,060, published Feb. 18, 1959, by Thomas Hedley & Co.,Ltd.; U.S. Pat. No. 2,965,576, to E. R. Wilson, issued Dec. 20, 1960;U.S. Pat. No. 2,703,798, to A. M. Schwartz, issued Mar. 8, 1955; andU.S. Pat. No. 1,985,424, to Piggott, issued Dec. 25, 1934; each of whichare incorporated herein by reference in their entirety.

[0113] Other examples of nonionic surfactants include amine oxides.Amine oxides correspond to the general formula R₁R₂R₃N→O, wherein R₁contains an alkyl, alkenyl or monohydroxy alkyl radical of from about 8to about 18 carbon atoms, from 0 to about 10 ethylene oxide moieties,and from 0 to about 1 glyceryl moiety, and R₂ and R₃ contain from about1 to about 3 carbon atoms and from 0 to about 1 hydroxy group, e.g.,methyl, ethyl, propyl, hydroxyethyl, or hydroxypropyl radicals. Thearrow in the formula is a conventional representation of a semipolarbond. Examples of amine oxides suitable for use in this inventioninclude dimethyl-dodecylamine oxide, oleyldi(2-hydroxyethyl) amineoxide, dimethyloctylamine oxide, dimethyl-decylamine oxide,dimethyl-tetradecylamine oxide, 3,6,9-trioxaheptadecyldiethylamineoxide, di(2-hydroxyethyl)-tetradecylamine oxide,2-dodecoxyethyldimethylamine oxide,3-dodecoxy-2-hydroxypropyldi(3-hydroxypropyl)amine oxide,dimethylhexadecylamine oxide.

[0114] Nonlimiting examples of preferred nonionic surfactants for useherein are those selected form the group consisting of C8-C14 glucoseamides, C8-C14 alkyl polyglucosides, sucrose cocoate, sucrose laurate,lauramine oxide, cocoamine oxide, and mixtures thereof.

[0115] Cationic Lathering Surfactants

[0116] Cationic lathering surfactants are also useful in the articles ofthe present invention. Suitable cationic lathering surfactants include,but are not limited to, fatty amines, di-fatty quaternary amines,tri-fatty quaternary amines, imidazolinium quaternary amines, andcombinations thereof. Suitable fatty amines include monalkyl quaternaryamines such as cetyltrimethylammonium bromide. A suitable quaternaryamine is dialklamidoethyl hydroxyethylmonium methosulfate. The fattyamines, however, are preferred. It is preferred that a lather booster isused when the cationic lathering surfactant is the primary latheringsurfactant of the cleansing component. Additionally, nonionicsurfactants have been found to be particularly useful in combinationwith such cationic lathering surfactants.

[0117] Amphoteric Lathering Surfactants

[0118] The term “amphoteric lathering surfactant,” as used herein, isalso intended to encompass zwitterionic surfactants, which are wellknown to formulators skilled in the art as a subset of amphotericsurfactants.

[0119] A wide variety of amphoteric lathering surfactants can be used inthe compositions of the present invention. Particularly useful are thosewhich are broadly described as derivatives of aliphatic secondary andtertiary amines, preferably wherein the nitrogen is in a cationic state,in which the aliphatic radicals can be straight or branched chain andwherein one of the radicals contains an ionizable water solubilizinggroup, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate.

[0120] Nonlimiting examples of amphoteric surfactants useful in thecompositions of the present invention are disclosed in McCutcheon's,Detergents and Emulsifiers, North American edition (1986), published byallured Publishing Corporation; and McCutcheon's, Functional Materials,North American Edition (1992); both of which are incorporated byreference herein in their entirety.

[0121] Nonlimiting examples of amphoteric or zwitterionic surfactantsare those selected from the group consisting of betaines, sultaines,hydroxysultaines, alkyliminoacetates, iminodialkanoates,aminoalkanoates, and mixtures thereof.

[0122] Examples of betaines include the higher alkyl betaines, such ascoco dimethyl carboxymethyl betaine, lauryl dimethyl carboxymethylbetaine, lauryl dimethyl alpha-carboxyethyl betaine, cetyl dimethylcarboxymethyl betaine, cetyl dimethyl betaine (available as Lonzaine16SP from Lonza Corp.), lauryl bis-(2-hydroxyethyl) carboxymethylbetaine, oleyl dimethyl gamma-carboxypropyl betaine, laurylbis-(2-hydroxypropyl)alpha-carboxyethyl betaine, coco dimethylsulfopropyl betaine, lauryl dimethyl sulfoethyl betaine, laurylbis-(2-hydroxyethyl) sulfopropyl betaine, amidobetaines andamidosulfobetaines (wherein the RCONH(CH₂)₃ radical is attached to thenitrogen atom of the betaine), oleyl betaine (available as amphotericVelvetex OLB-50 from Henkel), and cocamidopropyl betaine (available asVelvetex BK-35 and BA-35 from Henkel).

[0123] Examples of sultaines and hydroxysultaines include materials suchas cocamidopropyl hydroxysultaine (available as Mirataine CBS fromRhone-Poulenc).

[0124] Preferred for use herein are amphoteric surfactants having thefollowing structure:

[0125] wherein R¹ is unsubstituted, saturated or unsaturated, straightor branched chain alkyl having from about 9 to about 22 carbon atoms.Preferred R¹ has from about 11 to about 18 carbon atoms; more preferablyfrom about 12 to about 18 carbon atoms; more preferably still from about14 to about 18 carbon atoms; m is an integer from 1 to about 3, morepreferably from about 2 to about 3, and more preferably about 3; n iseither 0 or 1, preferably 1; R² and R³ are independently selected fromthe group consisting of alkyl having from 1 to about 3 carbon atoms,unsubstituted or mono-substituted with hydroxy, preferred R² and R³ areCH₃; X is selected from the group consisting of CO₂, SO₃ and SO₄; R⁴ isselected from the group consisting of saturated or unsaturated, straightor branched chain alkyl, unsubstituted or monosubstituted with hydroxy,having from 1 to about 5 carbon atoms. When X is CO₂, R⁴ preferably has1 or 3 carbon atoms, more preferably 1 carbon atom. When X is SO₃ orSO₄, R⁴ preferably has from about 2 to about 4 carbon atoms, morepreferably 3 carbon atoms.

[0126] Examples of amphoteric surfactants of the present inventioninclude the following compounds:

[0127] Cetyl dimethyl betaine (this material also has the CTFAdesignation cetyl betaine)

[0128] Cocamidopropylbetaine

[0129] wherein R has from about 9 to about 13 carbon atoms

[0130] Cocamidopropyl hydroxy sultaine

[0131] wherein R has from about 9 to about 13 carbon atoms,

[0132] Examples of other useful amphoteric surfactants arealkyliminoacetates, and iminodialkanoates and aminoalkanoates of theformulas RN[CH₂)_(m)CO₂M]₂ and RNH(CH₂)_(m)CO₂M wherein m is from 1 to4, R is a C₈-C₂₂ alkyl or alkenyl, and M is H, alkali metal, alkalineearth metal ammonium, or alkanolammonium. Also included areimidazolinium and ammonium derivatives. Specific examples of suitableamphoteric surfactants include sodium 3-dodecyl-aminopropionate, sodium3-dodecylaminopropane sulfonate, N-higher alkyl aspartic acids such asthose produced according to the teaching of U.S. Pat. No. 2,438,091which is incorporated herein by reference in its entirety; and theproducts sold under the trade name “Miranol” and described in U.S. Pat.No. 2,528,378, which is incorporated herein by reference in itsentirety. Other examples of useful amphoterics include amphotericphosphates, such as coamidopropyl PG-dimonium chloride phosphate(commercially available as Monaquat PTC, from Mona Corp.). Also usefulare amphoacetates such as disodium lauroamphodiacetate, sodiumlauroamphoacetate, and mixtures thereof.

[0133] Preferred lathering surfactants are selected from the groupconsisting of anionic lathering surfactants selected from the groupconsisting of ammonium lauroyl sarcosinate, sodium trideceth sulfate,sodium lauroyl sarcosinate, ammonium laureth sulfate, sodium laurethsulfate, ammonium lauryl sulfate, sodium lauryl sulfate, ammonium cocoylisethionate, sodium cocoyl isethionate, sodium lauroyl isethionate,sodium cetyl sulfate, sodium monolauryl phospate, sodium cocoglycerylether sulfonate, sodium C₉-C₂₂ soap, and combinations thereof; nonioniclathering surfactants selected from the group consisting of lauramineoxide, cocoamine oxide, decyl polyglucose, lauryl polyglucose, sucrosecocoate, C12-14 glucosamides, sucrose laurate, and combinations thereof;cationic lathering surfactants selected from the group consisting offatty amines, di-fatty quaternary amines, tri-fatty quaternary amines,imidazolinium quaternary amines, and combinations thereof; amphotericlathering surfactants selected from the group consisting of disodiumlauroamphodiacetate, sodium lauroamphoacetate, cetyl dimethyl betaine,cocoamidopropyl betaine, cocoamidopropyl hydroxy sultaine, andcombinations thereof.

[0134] Therapeutic Benefit Component

[0135] In certain embodiments of the present invention, the articlesessentially comprise a therapeutic benefit component. This benefitcomponent is disposed adjacent to the water insoluble substrate andcomprises from about 10% to about 1000%, more preferably, from about 10%to about 500%, and most preferably from about 10% to about 250%, byweight of the water insoluble substrate, of a therapeutic benefit agent.Preferably, the therapeutic benefit agent is selected from the groupconsisting of hydrophobic conditioning agents, hydrophilic conditioningagents, structured conditioning agents, and combinations thereof.

[0136] Hydrophobic Conditioning Agents

[0137] The articles of the present invention may comprise one or morehydrophobic conditioning agents which are useful for providing aconditioning benefit to the skin or hair during the use of the article.The articles of present invention preferably comprise from about 0.5% toabout 1,000%, more preferably from about 1% to about 200%, and mostpreferably from about 10% to about 100%, by weight of the waterinsoluble substrate, of a hydrophobic conditioning agent.

[0138] The hydrophobic conditioning agent may be selected from one ormore hydrophobic conditioning agents such that the weighted arithmeticmean solubility parameter of the hydrophobic conditioning agent is lessthan or equal to 10.5. It is recognized, based on this mathematicaldefinition of solubility parameters, that it is possible, for example,to achieve the required weighted arithmetic mean solubility parameter,i.e., less than or equal to 10.5, for a hydrophobic conditioning agentcomprising two or more compounds if one of the compounds has anindividual solubility parameter greater than 10.5.

[0139] Solubility parameters are well known to the formulation chemistof ordinary skill in the art and are routinely used as a guide fordetermining compatibility's and solubilities of materials in theformulation process.

[0140] The solubility parameter of a chemical compound, δ, is defined asthe square root of the cohesive energy density for that compound.Typically, a solubility parameter for a compound is calculated fromtabulated values of the additive group contributions for the heat ofvaporization and molar volume of the components of that compound, usingthe following equation:$\delta = \lbrack \frac{\sum\limits_{i}E_{i}}{\sum\limits_{i}m_{i}} \rbrack^{\frac{1}{2}}$

[0141] wherein Σ_(i)E_(i)=the sum of the heat of vaporization additivegroup contributions, and

[0142] Σ_(i)m_(i)=the sum of the molar volume additive groupcontributions

[0143] Standard tabulations of heat of vaporization and molar volumeadditive group contributions for a wide variety of atoms and groups ofatoms are collected in Barton, A. F. M. Handbook of SolubilityParameters, CRC Press, Chapter 6, Table 3, pp. 64-66 (1985), which isincorporated by reference herein in its entirety. The above solubilityparameter equation is described in Fedors, R. F., “A Method forEstimating Both the Solubility Parameters and Molar Volumes of Liquids”,Polymer Engineering and Science, vol. 14, no. 2, pp. 147-154 (February1974), which is incorporated by reference herein in its entirety.

[0144] Solubility parameters obey the law of mixtures such that thesolubility parameter for a mixture of materials is given by the weightedarithmetic mean (i.e. the weighted average) of the solubility parametersfor each component of that mixture. See, Handbook of Chemistry andPhysics, 57th edition, CRC Press, p. C-726 (1976-1977), which isincorporated by reference herein in its entirety.

[0145] Formulation chemists typically report and use solubilityparameters in units of (cal/cm³)^(1/2). The tabulated values of additivegroup contributions for heat of vaporization in the Handbook ofSolubility Parameters are reported in units of kJ/mol. However, thesetabulated heat of vaporization values are readily converted to cal/molusing the following well-known relationships:

1 J/mol=0.239006 cal/mol and 1000 J=1 kJ.

[0146] See Gordon, A. J. et al., The Chemist's Companion, John Wiley &Sons, pp. 456-463, (1972), which is incorporated by reference herein inits entirety.

[0147] Solubility parameters have also been tabulated for a wide varietyof chemical materials. Tabulations of solubility parameters are found inthe above-cited Handbook of Solubility Parameters. Also, see “SolubilityEffects In Product, Package, Penetration, And Preservation”, C. D.Vaughan, Cosmetics and Toiletries, vol. 103, October 1988, pp. 47-69,which is incorporated by reference herein in its entirety.

[0148] Nonlimiting examples of hydrophobic conditioning agents includethose selected from the group consisting of mineral oil, petrolatum,lecithin, hydrogenated lecithin, lanolin, lanolin derivatives, C7-C40branched chain hydrocarbons, C1-C30 alcohol esters of C1-C30 carboxylicacids, C1-C30 alcohol esters of C2-C30 dicarboxylic acids,monoglycerides of C1-C30 carboxylic acids, diglycerides of C1-C30carboxylic acids, triglycerides of C1-C30 carboxylic acids, ethyleneglycol monoesters of C1-C30 carboxylic acids, ethylene glycol diestersof C1-C30 carboxylic acids, propylene glycol monoesters of C1-C30carboxylic acids, propylene glycol diesters of C1-C30 carboxylic acids,C1-C30 carboxylic acid monoesters and polyesters of sugars,polydialkylsiloxanes, polydiarylsiloxanes, polyalkarylsiloxanes,cylcomethicones having 3 to 9 silicon atoms, vegetable oils,hydrogenated vegetable oils, polypropylene glycol C4-C20 alkyl ethers,di C8-C30 alkyl ethers, and combinations thereof.

[0149] Mineral oil, which is also known as petrolatum liquid, is amixture of liquid hydrocarbons obtained from petroleum. See The MerckIndex, Tenth Edition, Entry 7048, p. 1033 (1983) and InternationalCosmetic Ingredient Dictionary, Fifth Edition, vol. 1, p.415-417 (1993),which are incorporated by reference herein in their entirety.

[0150] Petrolatum, which is also known as petroleum jelly, is acolloidal system of nonstraight-chain solid hydrocarbons andhigh-boiling liquid hydrocarbons, in which most of the liquidhydrocarbons are held inside the micelles. See The Merck Index, TenthEdition, Entry 7047, p. 1033 (1983); Schindler, Drug. Cosmet. Ind., 89,36-37, 76, 78-80, 82 (1961); and International Cosmetic IngredientDictionary, Fifth Edition, vol. 1, p. 537 (1993), which are incorporatedby reference herein in their entirety.

[0151] Lecithin is also useful as a hydrophobic conditioning agent. Itis a naturally occurring mixture of the diglycerides of certain fattyacids, linked to the choline ester of phosphoric acid.

[0152] Straight and branched chain hydrocarbons having from about 7 toabout 40 carbon atoms are useful herein. Nonlimiting examples of thesehydrocarbon materials include dodecane, isododecane, squalane,cholesterol, hydrogenated polyisobutylene, docosane (i.e. a C₂₂hydrocarbon), hexadecane, isohexadecane (a commercially availablehydrocarbon sold as Permethyl® 101A by Presperse, South Plainfield,N.J.). Also useful are the C7-C40 isoparaffins, which are C7-C40branched hydrocarbons. Polydecene, a branched liquid hydrocarbon, isalso useful herein and is commercially available under the tradenamesPuresyn 100® and Puresyn 3000® from Mobile Chemical (Edison, N.J.).

[0153] Also useful are C1-C30 alcohol esters of C1-C30 carboxylic acidsand of C2-C30 dicarboxylic acids, including straight and branched chainmaterials as well as aromatic derivatives. Also useful are esters suchas monoglycerides of C1-C30 carboxylic acids, diglycerides of C1-C30carboxylic acids, triglycerides of C1-C30 carboxylic acids, ethyleneglycol monoesters of C1-C30 carboxylic acids, ethylene glycol diestersof C1-C30 carboxylic acids, propylene glycol monoesters of C1-C30carboxylic acids, and propylene glycol diesters of C1-C30 carboxylicacids. Straight chain, branched chain and aryl carboxylic acids areincluded herein. Also useful are propoxylated and ethoxylatedderivatives of these materials. Nonlimiting examples include diisopropylsebacate, diisopropyl adipate, isopropyl myristate, isopropyl palmitate,myristyl propionate, ethylene glycol distearate, 2-ethylhexyl palmitate,isodecyl neopentanoate, di-2-ethylhexyl maleate, cetyl palmitate,myristyl myristate, stearyl stearate, cetyl stearate, behenyl behenrate,dioctyl maleate, dioctyl sebacate, diisopropyl adipate, cetyl octanoate,diisopropyl dilinoleate, carpylic/capric triglyceride, PEG-6caprylic/capric triglyceride, PEG-8 caprylic/capric triglyceride, andcombinations thereof.

[0154] Also useful are various C1-C30 monoesters and polyesters ofsugars and related materials. These esters are derived from a sugar orpolyol moiety and one or more carboxylic acid moieties. Depending on theconstituent acid and sugar, these esters can be in either liquid orsolid form at room temperature. Examples of liquid esters include:glucose tetraoleate, the glucose tetraesters of soybean oil fatty acids(unsaturated), the mannose tetraesters of mixed soybean oil fatty acids,the galactose tetraesters of oleic acid, the arabinose tetraesters oflinoleic acid, xylose tetralinoleate, galactose pentaoleate, sorbitoltetraoleate, the sorbitol hexaesters of unsaturated soybean oil fattyacids, xylitol pentaoleate, sucrose tetraoleate, sucrose pentaoletate,sucrose hexaoleate, sucrose hepatoleate, sucrose octaoleate, andmixtures thereof. Examples of solid esters include: sorbitol hexaesterin which the carboxylic acid ester moieties are palmitoleate andarachidate in a 1:2 molar ratio; the octaester of raffinose in which thecarboxylic acid ester moieties are linoleate and behenate in a 1:3 molarratio; the heptaester of maltose wherein the esterifying carboxylic acidmoieties are sunflower seed oil fatty acids and lignocerate in a 3:4molar ratio; the octaester of sucrose wherein the esterifying carboxylicacid moieties are oleate and behenate in a 2:6 molar ratio; and theoctaester of sucrose wherein the esterifying carboxylic acid moietiesare laurate, linoleate and behenate in a 1:3:4 molar ratio. A preferredsolid material is sucrose polyester in which the degree ofesterification is 7-8, and in which the fatty acid moieties are C18mono- and/or di-unsaturated and behenic, in a molar ratio ofunsaturates:behenic of 1:7 to 3:5. A particularly preferred solid sugarpolyester is the octaester of sucrose in which there are about 7 behenicfatty acid moieties and about 1 oleic acid moiety in the molecule. Othermaterials include cottonseed oil or soybean oil fatty acid esters ofsucrose. The ester materials are further described in, U.S. Pat. No.2,831,854, U.S. Pat. No. 4,005,196, to Jandacek, issued Jan. 25, 1977;U.S. Pat. No. 4,005,195, to Jandacek, issued Jan. 25, 1977, U.S. Pat.No. 5,306,516, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No.5,306,515, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No.5,305,514, to Letton et al., issued Apr. 26, 1994; U.S. Pat. No.4,797,300, to Jandacek et al., issued Jan. 10, 1989; U.S. Pat. No.3,963,699, to Rizzi et al, issued Jun. 15, 1976; U.S. Pat. No.4,518,772, to Volpenhein, issued May 21, 1985; and U.S. Pat. No.4,517,360, to Volpenhein, issued May 21, 1985; each of which isincorporated by reference herein in its entirety.

[0155] Nonvolatile silicones such as polydialkylsiloxanes,polydiarylsiloxanes, and polyalkarylsiloxanes are also useful oils.These silicones are disclosed in U.S. Pat. No. 5,069,897, to Orr, issuedDec. 3, 1991, which is incorporated by reference herein in its entirety.The polyalkylsiloxanes correspond to the general chemical formulaR₃SiO[R₂SiO]_(x)SiR₃ wherein R is an alkyl group (preferably R is methylor ethyl, more preferably methyl) and x is an integer up to about 500,chosen to achieve the desired molecular weight. Commercially availablepolyalkylsiloxanes include the polydimethylsiloxanes, which are alsoknown as dimethicones, nonlimiting examples of which include theVicasil® series sold by General Electric Company and the Dow Corning®200 series sold by Dow Corning Corporation. Specific examples ofpolydimethylsiloxanes useful herein include Dow Corning® 225 fluidhaving a viscosity of 10 centistokes and a boiling point greater than200° C., and Dow Corning® 200 fluids having viscosities of 50, 350, and12,500 centistokes, respectively, and boiling points greater than 200°C. Also useful are materials such as trimethylsiloxysilicate, which is apolymeric material corresponding to the general chemical formula[(CH₂)₃SiO_(1/2)]_(x)[SiO₂]y, wherein x is an integer from about 1 toabout 500 and y is an integer from about 1 to about 500. A commerciallyavailable trimethylsiloxysilicate is sold as a mixture with dimethiconeas Dow Corning® 593 fluid. Also useful herein are dimethiconols, whichare hydroxy terminated dimethyl silicones. These materials can berepresented by the general chemical formulas R₃SiO[R₂SiO]_(x)SiR₂OH andHOR₂SiO[R₂SiO]_(x)SiR₂OH wherein R is an alkyl group (preferably R ismethyl or ethyl, more preferably methyl) and x is an integer up to about500, chosen to achieve the desired molecular weight. Commerciallyavailable dimethiconols are typically sold as mixtures with dimethiconeor cyclomethicone (e.g. Dow Corning® 1401, 1402, and 1403 fluids). Alsouseful herein are polyalkylaryl siloxanes, with polymethylphenylsiloxanes having viscosities from about 15 to about 65 centistokes at25° C. being preferred. These materials are available, for example, asSF 1075 methylphenyl fluid (sold by General Electric Company) and 556Cosmetic Grade phenyl trimethicone fluid (sold by Dow CorningCorporation). Alkylated silicones such as methyldecyl silicone andmethyloctyl silicone are useful herein and are commercially availablefrom General Electric Company. Also useful herein are alkyl modifiedsiloxanes such as alkyl methicones and alkyl dimethicones wherein thealkyl chain contains 10 to 50 carbons. Such siloxanes are commerciallyavailable under the tradenames ABIL WAX 9810 (C₂₄-C₂₈ alkyl methicone)(sold by Goldschmidt) and SF1632 (cetearyl methicone)(sold by GeneralElectric Company).

[0156] Vegetable oils and hydrogenated vegetable oils are also usefulherein. Examples of vegetable oils and hydrogenated vegetable oilsinclude safflower oil, castor oil, coconut oil, cottonseed oil, menhadenoil, palm kernel oil, palm oil, peanut oil, soybean oil, rapeseed oil,linseed oil, rice bran oil, pine oil, sesame oil, sunflower seed oil,hydrogenated safflower oil, hydrogenated castor oil, hydrogenatedcoconut oil, hydrogenated cottonseed oil, hydrogenated menhaden oil,hydrogenated palm kernel oil, hydrogenated palm oil, hydrogenated peanutoil, hydrogenated soybean oil, hydrogenated rapeseed oil, hydrogenatedlinseed oil, hydrogenated rice bran oil, hydrogenated sesame oil,hydrogenated sunflower seed oil, and mixtures thereof.

[0157] Also useful are C4-C20 alkyl ethers of polypropylene glycols,C1-C20 carboxylic acid esters of polypropylene glycols, and di-C8-C30alkyl ethers. Nonlimiting examples of these materials include PPG-14butyl ether, PPG-15 stearyl ether, dioctyl ether, dodecyl octyl ether,and mixtures thereof.

[0158] Hydrophobic chelating agents are also useful herein ashydrophobic conditioning agents. Suitable agents are described in U.S.Pat. No. 4,387,244, issued to Scanlon et al. on Jun. 7, 1983, andcopending U.S. patent application Ser. Nos. 09/258,747 and 09/259,485,filed in the names of Schwartz et al. on Feb. 26, 1999.

[0159] Hydrophilic Conditioning Agents

[0160] The articles of the present invention may optionally comprise oneor more hydrophilic conditioning agents. Nonlimiting examples ofhydrophilic conditioning agents include those selected from the groupconsisting of polyhydric alcohols, polypropylene glycols, polyethyleneglycols, ureas, pyrolidone carboxylic acids, ethoxylated and/orpropoxylated C3-C6 diols and triols, alpha-hydroxy C2-C6 carboxylicacids, ethoxylated and/or propoxylated sugars, polyacrylic acidcopolymers, sugars having up to about 12 carbons atoms, sugar alcoholshaving up to about 12 carbon atoms, and mixtures thereof. Specificexamples of useful hydrophilic conditioning agents include materialssuch as urea; guanidine; glycolic acid and glycolate salts (e.g.,ammonium and quaternary alkyl ammonium); lactic acid and lactate salts(e.g., ammonium and quaternary alkyl ammonium); sucrose, fructose,glucose, eruthrose, erythritol, sorbitol, mannitol, glycerol,hexanetriol, propylene glycol, butylene glycol, hexylene glycol, and thelike; polyethylene glycols such as PEG-2, PEG-3, PEG-30, PEG-50,polypropylene glycols such as PPG-9, PPG-12, PPG-15, PPG-17, PPG-20,PPG-26, PPG-30, PPG-34; alkoxylated glucose; hyaluronic acid; cationicskin conditioning polymers (e.g., quaternary ammonium polymers such asPolyquaternium polymers); and mixtures thereof. Glycerol, in particular,is a preferred hydrophilic conditioning agent in the articles of thepresent invention. Also useful are materials such as aloe vera in any ofits variety of forms (e.g., aloe vera gel), chitosan and chitosanderivatives, e.g., chitosan lactate, lactamide monoethanolamine;acetamide monoethanolamine; and mixtures thereof. Also useful arepropoxylated glycerols as described in propoxylated glycerols describedin U.S. Pat. No. 4,976,953, to Orr et al., issued Dec. 11, 1990, whichis incorporated by reference herein in its entirety.

[0161] The therapeutic benefit component may be made into a variety offorms. In one embodiment of the present invention, the therapeuticbenefit component is in the form of an emulsion. For instance,oil-in-water, water-in-oil, water-in-oil-in-water, andoil-in-water-in-silicone emulsions are useful herein. As used in thecontext of emulsions, “water” may refer not only to water but also watersoluble or water miscible agents like glycerin.

[0162] Preferred therapeutic benefit components comprise an emulsion,which further comprises an aqueous phase and an oil phase. As will beunderstood by the skilled artisan, a given component will distributeprimarily into either the aqueous or oil phase, depending on the watersolubility/dispersibility of the therapeutic benefit agent in thecomponent. In one embodiment, the oil phase comprises one or morehydrophobic conditioning agents. In another embodiment, the aqueousphase comprises one or more hydrophilic conditioning agents.

[0163] Therapeutic benefit components of the present invention, whichare emulsion form, generally contain an aqueous phase and an oil orlipid phase. Suitable oils or lipids may be derived from animals,plants, or petroleum and may be natural or synthetic (i.e., man-made).Such oils are discussed above in the Hydrophobic Conditioning Agentssection. Suitable aqueous phase components include the HydrophilicConditioning Agents, which are discussed above. Preferred emulsion formsinclude water-in-oil emulsions, water-in-silicone emulsions, and otherinverse emulsions. Additionally, preferred emulsions also contain ahydrophilic conditioning agent such as glycerin such that aglycerin-in-oil emulsion results.

[0164] Therapeutic benefit components in emulsion form will preferablyfurther contain from about 1% to about 10%, more preferably from about2% to about 5%, of an emulsifier, based on the weight of therapeuticbenefit component. Emulsifiers may be nonionic, anionic or cationic.Suitable emulsifiers are disclosed in, for example, U.S. Pat. No.3,755,560, issued Aug. 28, 1973, Dickert et al.; U.S. Pat. No.4,421,769, issued Dec. 20, 1983, Dixon et al.; and McCutcheon'sDetergents and Emulsifiers, North American Edition, pages 317-324(1986). Therapeutic benefit components in emulsion form may also containan anti-foaming agent to minimize foaming upon application to the skin.Anti-foaming agents include high molecular weight silicones and othermaterials well known in the art for such use.

[0165] The therapeutic benefit component may also be in the form of amicroemulsion. As used herein, “microemulsion” refers to thermodynamicstable mixtures of two immiscible solvents (one apolar and the otherpolar) stabilized by an amphiphilic molecule, a surfactant. Preferredmicroemulsions include water-in-oil microemulsions.

[0166] Structured Conditioning Agents

[0167] The therapeutic benefit component may comprise structuredconditioning agents. Suitable structured conditioning agents include,but are not limited to, vesicular structures such as ceramides,liposomes, and the like.

[0168] In another embodiment, the therapeutic benefit agents of thebenefit component are comprised within a coacervate-forming composition.Preferably, the coacervate-forming composition comprises a cationicpolymer, an anionic surfactant, and a dermatologically acceptablecarrier for the polymer and surfactant. The cationic polymer may beselected from the group consisting of natural backbone quaternaryammonium polymers, synthetic backbone quaternary ammonium polymers,natural backbone amphoteric type polymers, synthetic backbone amphoterictype polymers, and combinations thereof.

[0169] More preferably, the cationic polymer is selected from the groupconsisting of natural backbone quaternary ammonium polymers selectedfrom the group consisting of Polyquaternium-4, Polyquaternium-10,Polyquaternium-24, PG-hydroxyethylcellulose alkyldimonium chlorides,guar hydroxypropyltrimonium chloride, hydroxypropylguarhydroxypropyltrimonium chloride, and combinations thereof; syntheticbackbone quaternary ammonium polymers selected from the group consistingof Polyquaternium-2, Polyquaternium-6, Polyquaternium-7,Polyquaternium-11, Polyquaternium-16, Polyquaternium-17,Polyquaternium-18, Polyquaternium-28, Polyquaternium-32,Polyquaternium-37, Polyquaternium-43, Polyquaternium-44,Polyquaternium-46, polymethacylamidopropyl trimonium chloride,acrylamidopropyl trimonium chloride/acrylamide copolymer, andcombinations thereof; natural backbone amphoteric type polymers selectedfrom the group consisting of chitosan, quaternized proteins, hydrolyzedproteins, and combinations thereof; synthetic backbone amphoteric typepolymers selected from the group consisting of Polyquaternium-22,Polyquaternium-39, Polyquaternium-47, adipicacid/dimethylaminohydroxypropyl diethylenetriamine copolymer,polyvinylpyrrolidone/dimethylyaminoethyl methacyrlate copolymer,vinylcaprolactam/polyvinylpyrrolidone/dimethylaminoethylmethacrylatecopolymer,vinaylcaprolactam/polyvinylpyrrolidone/dimethylaminopropylmethacrylamideterpolymer, polyvinylpyrrolidone/dimethylaminopropylmethacrylamidecopolymer, polyamine, and combinations thereof; and combinationsthereof. Even more preferably, the cationic polymer is a syntheticbackbone amphoteric type polymer. Even still more preferably, thecationic polymer is a polyamine.

[0170] When the cationic polymer is a polyamine, it is preferred thatthe cationic polyamine polymer be selected from the group consisting ofpolyethyleneimines, polyvinylamines, polypropyleneimines, polylysinesand combinations thereof. Even more preferably, the cationic polyaminepolymer is a polyethyleneimine.

[0171] In certain embodiments in which the cationic polymer is apolyamine, the polyamine may be hydrophobically or hydrophilicallymodified. In this instance, the cationic polyamine polymer is selectedfrom the group consisting of benzylated polyamines, ethoxylatedpolyamines, propoxylated polyamines, alkylated polyamines, amidatedpolyamines, esterified polyamines and combinations thereof. Thecoacervate-forming composition comprises from about 0.01% to about 20%,more preferably from about 0.05% to about 10%, and most preferably fromabout 0.1% to about 5%, by weight of the coacervate-forming composition,of the cationic polymer.

[0172] Suitable anionic surfactants include those discussed above asrelated to the “cleansing component.” Preferably, for thecoacervate-forming composition, the anionic surfactant is selected fromthe group consisting of sarcosinates, glutamates, sodium alkyl sulfates,ammonium alkyl sulfates, sodium alkyleth sulfates, ammonium alkylethsulfates, ammonium laureth-n-sulfates, sodium laureth-n-sulfates,isethionates, glycerylether sulfonates, sulfosuccinates and combinationsthereof. More preferably, the anionic surfactant is selected from thegroup consisting of sodium lauroyl sarcosinate, monosodium lauroylglutamate, sodium alkyl sulfates, ammonium alkyl sulfates, sodiumalkyleth sulfates, ammonium alkyleth sulfates, and combinations thereof.

[0173] Suitable coacervate-forming compositions are further described incopending U.S. patent applications Ser. No. 09/397,747, filed in thename of Schwartz et al.; Ser. No. 09/397,746, filed in the name ofHeinrich et al.; Ser. No. 09/397,712, filed in the name of Schwartz etal.; Ser. No. 09/397,723, filed in the name of Heinrich et al.; and Ser.No. 09/397,722, filed in the name of Venkitaraman et al.; each of whichwere filed on Sep. 16, 1999.

[0174] Alternatively, the coacervate-forming composition may comprise ananionic polymer, a cationic surfactant, and a dermatologicallyacceptable carrier for the polymer and surfactant. The anionic polymermay be selected from the group consisting of polyacrylic acid polymers,polyacrylamide polymers, copolymers of acrylic acid, acrylamide, andother natural or synthetic polymers (e.g., polystyrene, polybutene,polyurethane, etc.), naturally derived gums, and combinations thereof.Suitable gums include alginates (e.g., propylene glycol alginate),pectins, chitosans (e.g., chitosan lactate), and modified gums (e.g.,starch octenyl succinate), and combinations thereof. More preferably,the anionic polymer is selected from the group consisting of polyacrylicacid polymers, polyacrylamide polymers, pectins, chitosans, andcombinations thereof. Preferred articles of the present inventioncomprise from about 0.01% to about 20%, more preferably from about 0.05%to about 10%, and most preferably from about 0.1% to about 5%, by weightof the coacervate-forming composition, of the anionic polymer. Suitablecationic surfactants include, but are not limited to, those discussedherein.

[0175] The therapeutic benefit component of the article is suitable forproviding therapeutic or aesthetic skin or hair benefits by depositiononto such surfaces of not only conditioning agents but also variousagents including, but not limited to, anti-acne actives, anti-wrinkleactives, anti-microbial actives, anti-fungal actives, anti-inflammatoryactives, topical anesthetic actives, artificial tanning agents andaccelerators, anti-viral agents, enzymes, sunscreen actives,anti-oxidants, skin exfoliating agents, and combinations thereof.

[0176] It should also be understood that the therapeutic benefitcomponent may be contained within the cleansing component of the presentinvention or vice versa such that they form a unitary component withindistinguishable ingredients.

[0177] Surface to Saturation Ratio Methodology

[0178] The articles of the present invention have the therapeuticbenefit component substantially on the surface of the substrate. By“substantially on the surface of the substrate” is meant that thesurface to saturation ratio is greater than about 1.25, preferablygreater than about 1.5, more preferably greater than about 2.0, evenmore preferably greater than about 2.25, and most preferably greaterthan 2.5. The surface to saturation ratio is a ratio of the measurementof benefit agent on the surface of the substrate. These measurements areobtained from Attenuated Total Reflectance (ATR) FT-IR Spectroscopy theuse of which is well known to one skilled in the art of analyticalchemistry.

[0179] Many conventional methods of application of conditioning agentsto substrates employ processes and/or product rheologies unsuitable forthe purposes of the present invention. For example, a process to dip thesubstrate web in a fluid bath of conditioning agent and then squeeze thesubstrate web through metering rolls, so called “dip and nip”processing, applies conditioning agent through the entire substrate andtherefore does not afford opportunity for effective direct transfer ofthe composition off the cloth and onto another surface during use.Furthermore, many of the articles of the present invention utilizesufficient loadings of conditioning agent onto substrates to provide aneffective whole body benefit, usually requiring about 100-200% loadingrates based on the weight of the dry substrate. Known personal careimplements that use these high loading levels essentially avoid dealingwith aesthetic issues that can result from these high loadings bydistributing the loading evenly throughout the substrate, including thesubstrate interior. Applicants have surprisingly found that highloadings of conditioning agent can be maintained on the surface of thearticle, thus advantageously affording opportunity for direct transferof the benefit agents from the substrate to the surface to be treatedduring use, while delivering improved aesthetics by the compositions ofthe present invention.

[0180] The procedure to obtain the measurements is as follows:

[0181] Instrumental Setup: A BioRad FTS-7 spectrometer, manufactured byBio Rad Labs, Digital Laboratory Division, located in Cambridge, Mass.,is used to collect the infrared spectra. Typically, the measurementsconsist of 100 scans at 4 cm⁻¹ resolution. The collection optics consistof a flat 60 deg ZnSe ATR crystal, manufactured by Graseby Specac, Inc.,located in Fairfield, Conn. Data is collected at 25° C. and analyzedusing Grams 386 software, distributed by Galactic Industries Corp.,located in Salem, N.H. Prior to measurement the crystal is cleaned witha suitable solvent. The sample is placed onto the ATR crystal and heldunder constant 4 kilogram weight.

[0182] Experimental Procedure

[0183] (1) Measure the reference (background) spectrum of the cleaned,air dried cell.

[0184] (2) First, select a substrate with no benefit agents applied toit, the substrate selected comprising the external surface of thearticle. Place substrate on top of the ATR crystal., external surfaceagainst the crystal. First lay the substrate flat on the measuringplatform. Then place a 4 kg. weight on top of the substrate. Then,measure the spectrum (typically 100 scans at 4 cm⁻¹ resolution). Thesubstrate acts as an internal standard because the absorbancy of thesubstrate alone is thus identified. Identify the main substrate peaksand wavenumbers.

[0185] (3) Repeat the procedure for the substrate of the article withbenefit agent applied to it. Identify the primary benefit agent's peakheights, which are the highest observed peaks that either do notcorrespond to a substrate peak as observed previously; or which maycorrespond to a previously observed substrate peak but which exhibit thegreatest percentage increase in absorbance due to presence of theconditioning agent. Record the wavenumber and absorbance of severalbenefit agent peaks.

[0186] (4) Select the substrate peak from the spectra determined in step3 which occurs at a wavenumber determined in step 2, but which does notcorrespond to one of the primary benefit agent peaks selected in step 3.Record the wavenumber selected and the absorbance from the absorbancespectrum in step 3.

[0187] (5) Calculate the ratio of each benefit agent's peak heightdetermined in step 3 to the substrate's peak height determined in step4. The highest number of the group represents the surface to saturationratio for the article.

[0188] The following contain some examples: Condi- tioner Substrate PeakPeak Substrate* and Peak Ht. Conditioner Ht. Ratio Batting (blend of0.0865 Glycerin 0.181 2.09 polyester heat bonded (C═O Peak at (C—O Peakat with 70% PET/PE 1710 cm⁻¹) 1030 cm⁻¹) bicomponent fiber) Batting(blend of 0.0865 Hydrocarbon 0.160 1.85 polyester heat bonded (C═O Peakat (C—H Peak at with 70% PET/PE 1710 cm⁻¹) 2923 cm⁻¹) bicomponent fiber)70% Rayon/30% 0.0333 Glycerin 0.0684 2.05 Polyester, (C═O Peak at (C—OPeak at hydroentangled 1710 cm⁻¹) 1030 cm⁻¹)

[0189] Moisture Retention Methodology

[0190] As described above, the articles of the present invention areconsidered to be “substantially dry”. As used herein, “substantiallydry” means that the articles of the present invention exhibit a MoistureRetention of less than about 0.95 gms, preferably less than about 0.75gms, even more preferably, less than about 0.5 gms, even more preferablyless than about 0.25 gms, even still more preferably less than about0.15 gms, and most preferably, less than about 0.1 gms. The MoistureRetention is indicative of the dry feel that users perceive upontouching the articles of the present invention as opposed to the feel of“wet” wipes.

[0191] In order to determine the Moisture Retention of the presentarticles and other disposable substrate-based products, the followingequipment and materials are needed. Bounty White Paper Towel Procter &Gamble SKU 37000 63037 Basis Weight = 42.14 gsm Balance Accurate to 0.0g Lexan 0.5″ thickness large enough to cover samples completely andweighs 1000 g Weight A 2000 g weight or combination to equal 2000 g

[0192] Next, weigh two paper towels separately and record each weight.Place one paper towel on flat surface (e.g. lab bench). Place the samplearticle on top of that towel. Place the other paper towel on top ofsample article. Next, place the Lexan and then the 2000 g weight(s) ontop of the sandwiched sample article. Wait 1 minute. After the minute,remove weight(s) and Lexan. Weigh the top and bottom paper towel andrecord the weight.

[0193] Calculate the Moisture Retention by subtracting the initial papertowel weight from the final weight (after 1 minute) for both the top andbottom paper towels. Add the weight differences obtained for the top andbottom paper towels. Assuming multiple articles are tested, average thetotal weight differences to obtain the Moisture Retention.

[0194] Multiple Article Embodiment

[0195] The articles of the present invention may also be packagedindividually or with additional articles suitable for providing separatebenefits not provided by the primary article, e.g., aesthetic,therapeutic, functional, or otherwise, thereby forming a personal carekit. The additional article of this personal care kit preferablycomprises a water insoluble substrate comprising at least one layer andeither a cleansing component containing a lathering surfactant or atherapeutic benefit component disposed onto or impregnated into thatlayer of the substrate of the additional article.

[0196] The additional article of the present invention may also serve afunctional benefit in addition to or in lieu of a therapeutic oraesthetic benefit. For instance, the additional article may be useful asa drying implement suitable for use to aid in the removal of water fromthe skin or hair upon completion of a showering or bathing experience.

[0197] Multiple Chambered Embodiment

[0198] The articles of the present invention may also comprise one ormore chambers. Such chambers or compartments result from the connection(e.g., bonding) of the substrate layers to one another at various locito define enclosed areas. These chambers are useful, e.g., forseparating various article components from one another, e.g., thesurfactant-containing cleansing component from a conditioning agent. Theseparated article components which provide a therapeutic or aesthetic orcleansing benefit may be released from the chambers in a variety of waysincluding, but not limited to, solubilization, emulsification,mechanical transfer, puncturing, popping, bursting, squeezing of thechamber or even peeling away a substrate layer which composes a portionof the chamber.

[0199] Option Components

[0200] The articles of the present invention may contain a variety ofother components such as are conventionally used in a given product typeprovided that they do not unacceptably alter the benefits of theinvention. These optional components should be suitable for applicationto human skin and hair, that is, when incorporated into the article theyare suitable for use in contact with human skin without undue toxicity,incompatibility, instability, allergic response, and the like, withinthe scope of sound medical or formulator's judgment. The CTFA CosmeticIngredient Handbook, Second Edition (1992) describes a wide variety ofnonlimiting cosmetic and pharmaceutical ingredients commonly used in theskin care industry, which are suitable for use in the articles of thepresent invention. Examples of these ingredient classes include:enzymes, abrasives, skin exfoliating agents, absorbents, aestheticcomponents such as fragrances, pigments, colorings/colorants, essentialoils, skin sensates, astringents, etc. (e.g., clove oil, menthol,camphor, eucalyptus oil, eugenol, menthyl lactate, witch hazeldistillate), anti-acne agents (e.g., resorcinol, sulfur, salicylic acid,erythromycin, zinc, etc.), anti-caking agents, antifoaming agents,additional antimicrobial agents (e.g., iodopropyl butylcarbamate),antioxidants, binders, biological additives, buffering agents, bulkingagents, chelating agents, chemical additives, colorants, cosmeticastringents, cosmetic biocides, denaturants, drug astringents, externalanalgesics, film formers or materials, e.g., polymers, for aiding thefilm-forming properties and substantivity of the composition (e.g.,copolymer of eicosene and vinyl pyrrolidone), humectants, opacifyingagents, pH adjusters, propellants, reducing agents, sequestrants, skinbleaching agents (or lightening agents) (e.g., hydroquinone, kojic acid,ascorbic acid, magnesium ascorbyl phosphate, ascorbyl glucosamine), skinsoothing and/or healing agents (e.g., panthenol and derivatives (e.g.,ethyl panthenol), aloe vera, pantothenic acid and its derivatives,allantoin, bisabolol, and dipotassium glycyrrhizinate), skin treatingagents, including agents for preventing, retarding, arresting, and/orreversing skin wrinkles (e.g., alpha-hydroxy acids such as lactic acidand glycolic acid and beta-hydroxy acids such as salicylic acid),thickeners, hydrocolloids, particular zeolites, and vitamins andderivatives thereof (e.g. tocopherol, tocopherol acetate, beta carotene,retinoic acid, retinol, retinoids, retinyl palmitate, niacin,niacinamide, and the like). The articles of the present invention mayinclude carrier components such as are known in the art. Such carrierscan include one or more compatible liquid or solid filler diluents orvehicles which are suitable for application to skin or hair.

[0201] The articles of the present invention may optionally contain oneor more of such optional components. Preferred articles optionallycontain a safe and effective amount of therapeutic benefit componentcomprising a therapeutic benefit agent selected from the groupconsisting of vitamin compounds, skin treating agents, anti-acneactives, anti-wrinkle actives, anti-skin atrophy actives,anti-inflammatory actives, topical anesthetics, artificial tanningactives and accelerators, anti-microbial actives, anti-fungal actives,sunscreen actives, anti-oxidants, skin exfoliating agents, andcombinations thereof. As used herein, “a safe and effective amount”means an amount of a compound or component sufficient to significantlyinduce a positive effect or benefit, but low enough to avoid seriousside effects, (e.g., undue toxicity or allergic reaction), i.e., toprovide a reasonable benefit to risk ratio, within the scope of soundmedical judgment.

[0202] The optional components useful herein can be categorized by theirtherapeutic or aesthetic benefit or their postulated mode of action.However, it is to be understood that the optional components usefulherein can in some instances provide more than one therapeutic oraesthetic benefit or operate via more than one mode of action.Therefore, classifications herein are made for the sake of convenienceand are not intended to limit the component to that particularapplication or applications listed. Also, when applicable, thepharmaceutically-acceptable salts of the components are useful herein.

[0203] Vitamin Compounds

[0204] The present articles may comprise vitamin compounds, precursors,and derivatives thereof. These vitamin compounds may be in eithernatural or synthetic form. Suitable vitamin compounds include, but arenot limited to, Vitamin A (e.g., beta carotene, retinoic acid, retinol,retinoids, retinyl palmitate, retinyl proprionate, etc.), Vitamin B(e.g., niacin, niacinamide, riboflavin, pantothenic acid, etc.), VitaminC (e.g., ascorbic acid, etc.), Vitamin D (e.g., ergosterol,ergocalciferol, cholecalciferol, etc.), Vitamin E (e.g., tocopherolacetate, etc.), and Vitamin K (e.g., phytonadione, menadione, phthiocol,etc.) compounds.

[0205] In particular, the articles of the present invention may comprisea safe and effective amount of a vitamin B₃ compound. Vitamin B₃compounds are particularly useful for regulating skin condition asdescribed in co-pending U.S. application Ser. No. 08/834,010, filed Apr.11, 1997 (corresponding to international publication WO 97/39733 A1,published Oct. 30, 1997) which is incorporated by reference herein inits entirety. The therapeutic component of the present inventionpreferably comprise from about 0.01% to about 50%, more preferably fromabout 0.1% to about 10%, even more preferably from about 0.5% to about10%, and still more preferably from about 1% to about 5%, mostpreferably from about 2% to about 5%, of the vitamin B₃ compound.

[0206] As used herein, “vitamin B₃ compound” means a compound having theformula:

[0207] wherein R is —CONH₂ (i.e., niacinamide), —COOH (i.e., nicotinicacid) or —CH₂OH (i.e., nicotinyl alcohol); derivatives thereof; andsalts of any of the foregoing.

[0208] Exemplary derivatives of the foregoing vitamin B₃ compoundsinclude nicotinic acid esters, including non-vasodilating esters ofnicotinic acid, nicotinyl amino acids, nicotinyl alcohol esters ofcarboxylic acids, nicotinic acid N-oxide and niacinamide N-oxide.

[0209] Examples of suitable vitamin B₃ compounds are well known in theart and are commercially available from a number of sources, e.g., theSigma Chemical Company (St. Louis, Mo.); ICN Biomedicals, Inc. (Irvin,Calif.) and Aldrich Chemical Company (Milwaukee, Wis.).

[0210] The vitamin compounds may be included as the substantially purematerial, or as an extract obtained by suitable physical and/or chemicalisolation from natural (e.g., plant) sources.

[0211] Skin Treating Agents

[0212] The articles of the present invention may contain one or moreskin treating agents. Suitable skin treating agents include thoseeffective for preventing, retarding, arresting, and/or reversing skinwrinkles. Examples of suitable skin treating agents include, but are notlimited to, alpha-hydroxy acids such as lactic acid and glycolic acidand beta-hydroxy acids such as salicylic acid.

[0213] Anti-Acne Actives

[0214] Examples of useful anti-acne actives for the articles of thepresent invention include, but are not limited to, the keratolytics suchas salicylic acid (o-hydroxybenzoic acid), derivatives of salicylic acidsuch as 5-octanoyl salicylic acid, and resorcinol; retinoids such asretinoic acid and its derivatives (e.g., cis and trans);sulfur-containing D and L amino acids and their derivatives and salts,particularly their N-acetyl derivatives, a preferred example of which isN-acetyl-L-cysteine; lipoic acid; antibiotics and antimicrobials such asbenzoyl peroxide, octopirox, tetracycline, 2,4,4′-trichloro-2′-hydroxydiphenyl ether, 3,4,4′-trichlorobanilide, azelaic acid and itsderivatives, phenoxyethanol, phenoxypropanol, phenoxyisopropanol, ethylacetate, clindamycin and meclocycline; sebostats such as flavonoids; andbile salts such as scymnol sulfate and its derivatives, deoxycholate,and cholate.

[0215] Anti-Wrinkle and Anti-Skin Atrophy Actives

[0216] Examples of anti-wrinkle and anti-skin atrophy actives useful forthe articles of the present invention include, but are not limited to,retinoic acid and its derivatives (e.g., cis and trans); retinol;retinyl esters; niacinamide, salicylic acid and derivatives thereof;sulfur-containing D and L amino acids and their derivatives and salts,particularly the N-acetyl derivatives, a preferred example of which isN-acetyl-L-cysteine; thiols, e.g., ethane thiol; hydroxy acids, phyticacid, lipoic acid; lysophosphatidic acid, and skin peel agents (e.g.,phenol and the like).

[0217] Non-Steroidal Anti-Inflammatory Actives (NSAIDS)

[0218] Examples of NSAIDS useful for the articles of the presentinvention include, but are not limited to, the following categories:propionic acid derivatives; acetic acid derivatives; fenamic acidderivatives; biphenylcarboxylic acid derivatives; and oxicams. All ofthese NSAIDS are fully described in U.S. Pat. No. 4,985,459 to Sunshineet al., issued Jan. 15, 1991, incorporated by reference herein in itsentirety. Examples of useful NSAIDS include acetyl salicylic acid,ibuprofen, naproxen, benoxaprofen, flurbiprofen, fenoprofen, fenbufen,ketoprofen, indoprofen, pirprofen, carprofen, oxaprozin, pranoprofen,miroprofen, tioxaprofen, suprofen, alminoprofen, tiaprofenic acid,fluprofen and bucloxic acid. Also useful are the steroidalanti-inflammatory drugs including hydrocortisone and the like.

[0219] Topical Anesthetics

[0220] Examples of topical anesthetic drugs useful for the articles ofthe present invention include, but are not limited to, benzocaine,lidocaine, bupivacaine, chlorprocaine, dibucaine, etidocaine,mepivacaine, tetracaine, dyclonine, hexylcaine, procaine, cocaine,ketamine, pramoxine, phenol, and pharmaceutically acceptable saltsthereof.

[0221] Artificial Tanning Actives and Accelerators

[0222] Examples of artificial tanning actives and accelerators usefulfor the articles of the present invention include, but are not limitedto, dihydroxyacetaone, tyrosine, tyrosine esters such as ethyltyrosinate, and phospho-DOPA.

[0223] Antimicrobial and Antifungal Actives

[0224] Examples of antimicrobial and antifungal actives useful for thearticles of the present invention include, but are not limited to,β-lactam drugs, quinolone drugs, ciprofloxacin, norfloxacin,tetracycline, erythromycin, amikacin, 2,4,4′-trichloro-2′-hydroxydiphenyl ether, 3,4,4′-trichlorocarbanilide, phenoxyethanol, phenoxypropanol, phenoxyisopropanol, doxycycline, capreomycin, chlorhexidine,chlortetracycline, oxytetracycline, clindamycin, ethambutol, hexamidineisethionate, metronidazole, pentamidine, gentamicin, kanamycin,lineomycin, methacycline, methenamine, minocycline, neomycin,netilmicin, paromomycin, streptomycin, tobramycin, miconazole,tetracycline hydrochloride, erythromycin, zinc erythromycin,erythromycin estolate, erythromycin stearate, amikacin sulfate,doxycycline hydrochloride, capreomycin sulfate, chlorhexidine gluconate,chlorhexidine hydrochloride, chlortetracycline hydrochloride,oxytetracycline hydrochloride, clindamycin hydrochloride, ethambutolhydrochloride, metronidazole hydrochloride, pentamidine hydrochloride,gentamicin sulfate, kanamycin sulfate, lineomycin hydrochloride,methacycline hydrochloride, methenamine hippurate, methenaminemandelate, minocycline hydrochloride, neomycin sulfate, netilmicinsulfate, paromomycin sulfate, streptomycin sulfate, tobramycin sulfate,miconazole hydrochloride, amanfadine hydrochloride, amanfadine sulfate,octopirox, parachlorometa xylenol, nystatin, tolnaftate, zinc pyrithioneand clotrimazole.

[0225] Anti-Viral Agents

[0226] The articles of the present invention may further comprise one ormore anti-viral agents. Suitable anti-viral agents include, but are notlimited to, metal salts (e.g., silver nitrate, copper sulfate, ironchloride, etc.) and organic acids (e.g., malic acid, salicylic acid,succinic acid, benzoic acid, etc.). In particular compositions whichcontain additional suitable anti-viral agents include those described incopending U.S. patent application Ser. No. 09/421,084 (Beerse et al.);Ser. No. 09/421,131 (Biedermann et al.); Ser. No. 09/420,646 (Morgan etal.); and Ser. No. 09/421,179 (Page et al.), which were each filed onOct. 19, 1999.

[0227] Enzymes

[0228] The article of the present invention may optionally include oneor more enzymes. Preferably, such enzymes are dermatologicallyacceptable. Suitable enzymes include, but are not limited to,keratinase, protease, amylase, subtilisin, etc.

[0229] Sunscreen Actives

[0230] Also useful herein are sunscreening actives. A wide variety ofsunscreening agents are described in U.S. Pat. No. 5,087,445, to Haffeyet al., issued Feb. 11, 1992; U.S. Pat. No. 5,073,372, to Turner et al.,issued Dec. 17, 1991; U.S. Pat. No. 5,073,371, to Turner et al. issuedDec. 17, 1991; and Segarin, et al., at Chapter VIII, pages 189 et seq.,of Cosmetics Science and Technology, all of which are incorporatedherein by reference in their entirety. Nonlimiting, examples ofsunscreens which are useful in the compositions of the present inventionare those selected from the group consisting of 2-ethylhexylp-methoxycinnamate, 2-ethylhexyl N,N-dimethyl-p-aminobenzoate,p-aminobenzoic acid, 2-phenylbenzimidazole-5-sulfonic acid, octocrylene,oxybenzone, homomenthyl salicylate, octyl salicylate,4,4′-methoxy-t-butyldibenzoylmethane, 4-isopropyl dibenzoylmethane,3-benzylidene camphor, 3-(4-methylbenzylidene)camphor, titanium dioxide,zinc oxide, silica, iron oxide, and mixtures thereof. Still other usefulsunscreens are those disclosed in U.S. Pat. No. 4,937,370, to Sabatelli,issued Jun. 26, 1990; and U.S. Pat. No. 4,999,186, to Sabatelli et al.,issued Mar. 12, 1991; these two references are incorporated by referenceherein in their entirety. Especially preferred examples of thesesunscreens include those selected from the group consisting of4-N,N-(2-ethylhexyl)methylaminobenzoic acid ester of2,4-dihydroxybenzophenone, 4-N,N-(2-ethylhexyl)methylaminobenzoic acidester with 4-hydroxydibenzoylmethane,4-N,N-(2-ethylhexyl)-methylaminobenzoic acid ester of2-hydroxy-4-(2-hydroxyethoxy)benzophenone,4-N,N-(2-ethylhexyl)-methylaminobenzoic acid ester of4-(2-hydroxyethoxy)dibenzoylmethane, and mixtures thereof. Exact amountsof sunscreens which can be employed will vary depending upon thesunscreen chosen and the desired Sun Protection Factor (SPF) to beachieved. SPF is a commonly used measure of photoprotection of asunscreen against erythema. See Federal Register, Vol. 43, No. 166, pp.38206-38269, Aug. 25, 1978, which is incorporated herein by reference inits entirety.

[0231] Hydrocolloids

[0232] Hydrocolloids may also be optionally included in the articles ofthe present invention. Hydrocolloids are well known in the art and arehelpful in extending the useful life of the surfactants contained in thecleansing component of the present invention such that the articles maylast throughout at least one entire showering or bathing experience.Suitable hydrocolloids include, but are not limited to, xanthan gum,carboxymethyl cellulose, hydroxyethyl cellulose, hydroxylpropylcellulose, methyl and ethyl cellulose, natural gums, gudras guar gum,bean gum, natural starches, deionitized starches (e.g., starch octenylsuccinate) and the like.

[0233] Exothermic Zeolites

[0234] Zeolites and other compounds which react exothermically whencombined with water may also be optionally included in the articles ofthe present invention.

[0235] Hydrogel Forming Polymeric Gelling Agents

[0236] In certain embodiments of the present invention, the articles mayoptionally comprise an aqueous gel, i.e., a “hydrogel”, formed from ahydrogel forming polymeric gelling agent and water. More specificallythe hydrogel is contained within the cleansing component or thetherapeutic benefit component of the article. When an aqueous gel ispresent, the articles preferably comprise from about 0.1% to about 100%,by weight of the water insoluble substrate, more preferably from about3% to about 50%, and most preferably from about 5% to about 35%, of ahydrogel forming polymeric gelling agent, calculated based on the dryweight of the hydrogel forming polymeric gelling agent.

[0237] In general, the hydrogel forming polymeric gelling agentmaterials of the present invention are at least partially crosslinkedpolymers prepared from polymerizable, unsaturated acid-containingmonomers which are water-soluble or become water-soluble uponhydrolysis. These include monoethylenically unsaturated compounds havingat least one hydrophilic radical, including (but not limited to)olefinically unsaturated acids and anhydrides which contain at least onecarbon-carbon olefinic double bond. With respect to these monomers,water-soluble means that the monomer is soluble in deionized water at25° C. at a level of at least 0.2%, preferably at least 1.0%.

[0238] Upon polymerization, monomeric units as described above willgenerally constitute from about 25 mole percent to 99.99 mole percent,more preferably from about 50 mole percent to 99.99 mole percent, mostpreferably at least about 75 mole percent of the polymeric gelling agentmaterial (dry polymer weight basis), of acid-containing monomers.

[0239] The hydrogel forming polymeric gelling agent herein is partiallycrosslinked to a sufficient degree preferably that is high enough suchthat the resulting polymer does not exhibit a glass transitiontemperature (Tg) below about 140° C., and accordingly, the term“hydrogel forming polymeric gelling agent,” as used herein, shall meanpolymers meeting this parameter. Preferably the hydrogel formingpolymeric gelling agent does not have a Tg below about 180° C., and morepreferably does not have a Tg prior to decomposition of the polymer, attemperatures of about 300° C. or higher. The Tg can be determined bydifferential scanning calorimetry (DSC) conducted at a heating rate of20.0° C./minute with 5 mg or smaller samples. The Tg is calculated asthe midpoint between the onset and endset of heat flow changecorresponding to the glass transition on the DSC heat capacity heatingcurve. The use of DSC to determine Tg is well known in the art, and isdescribed by B. Cassel and M. P. DiVito in “Use of DSC To ObtainAccurate Thermodynamic and Kinetic Data”, American Laboratory, January1994, pp 14-19, and by B. Wunderlich in Thermal Analysis, AcademicPress, Inc., 1990.

[0240] The hydrogel forming polymeric material is characterized ashighly absorbent and able to retain water in its absorbed or “gel”state. Preferred hydrogel forming polymeric gelling agent hereof will beable to absorb at least about 40 g water (deionized) per gram of gellingagent, preferably at least about 60 g/g, more preferably at least about80 g/g. These values, referred to as “Absorptive Capacity” herein can bedetermined according to the procedure in the Absorptive Capacity “TeaBag” test described above.

[0241] The hydrogel forming polymeric gelling agent hereof will, ingeneral, be at least partially crosslinked. Suitable cross-linkingagents are well know in the art and include, for example, (1) compoundshaving at least two polymerizable double bonds; (2) compounds having atleast one polymerizable double bond and at least one functional groupreactive with the acid-containing monomer material; (3) compounds havingat least two functional groups reactive with the acid-containing monomermaterial; and (4) polyvalent metal compounds which can form ioniccross-linkages.

[0242] Cross-linking agents having at least two polymerizable doublebonds include (i) di- or polyvinyl compounds such as divinylbenzene anddivinyltoluene; (ii) di- or poly-esters of unsaturated mono- orpoly-carboxylic acids with polyols including, for example, di- ortriacrylic acid esters of polyols such as ethylene glycol, trimethylolpropane, glycerine, or polyoxyethylene glycols; (iii) bisacrylamidessuch as N,N-methylenebisacrylamide; (iv) carbamyl esters that can beobtained by reacting polyisocyanates with hydroxyl group-containingmonomers; (v) di- or poly-allyl ethers of polyols; (vi) di- orpoly-allyl esters of polycarboxylic acids such as diallyl phthalate,diallyl adipate, and the like; (vii) esters of unsaturated mono- orpoly-carboxylic acids with mono-allyl esters of polyols such as acrylicacid ester of polyethylene glycol monoallyl ether; and (viii) di- ortri-allyl amine.

[0243] Cross-linking agents having at least one polymerizable doublebond and at least one functional group reactive with the acid-containingmonomer material include N-methylol acrylamide, glycidyl acrylate, andthe like. Suitable cross-linking agents having at least two functionalgroups reactive with the acid-containing monomer material includeglyoxal; polyols such as ethylene glycol and glycerol; polyamines suchas alkylene diamines (e.g., ethylene diamine), polyalkylene polyamines,polyepoxides, di- or polyglycidyl ethers and the like. Suitablepolyvalent metal cross-linking agents which can form ioniccross-linkages include oxides, hydroxides and weak acid salts (e.g.,carbonate, acetate and the like) of alkaline earth metals (e.g.,calcium, magnesium) and zinc, including, for example, calcium oxide andzinc diacetate.

[0244] Cross-linking agents of many of the foregoing types are describedin greater detail in Masuda et al., U.S. Pat. No. 4,076,663, issued Feb.28, 1978, and Allen et al., U.S. Pat. No. 4,861,539, issued Aug. 29,1989, both incorporated herein by reference. Preferred cross-linkingagents include the di- or polyesters of unsaturated mono- orpolycarboxylic acids mono-allyl esters of polyols, the bisacrylamides,and the di- or tri-allyl amines. Specific examples of especiallypreferred cross-linking agents include N,N′-methylenebisacrylamide andtrimethylol propane triacrylate.

[0245] The cross-linking agent will generally constitute from about0.001 mole percent to 5 mole percent of the resulting hydrogel-formingpolymeric material. More generally, the cross-linking agent willconstitute from about 0.01 mole percent to 3 mole percent of thehydrogel-forming polymeric gelling agent used herein.

[0246] The hydrogel forming polymeric gelling agents hereof may beemployed in their partially neutralized form. For purposes of thisinvention, such materials are considered partially neutralized when atleast 25 mole percent, and preferably at least 50 mole percent ofmonomers used to form the polymer are acid group-containing monomerswhich have been neutralized with a base. Suitable neutralizing basescations include hydroxides of alkali and alkaline earth metal (e.g. KOH,NaOH), ammonium, substituted ammonium, and amines such as amino alcohols(e.g., 2-amino-2-methyl-1,3-propanediol, diethanolamine, and2-amino-2-methyl-1-propanol. This percentage of the total monomersutilized which are neutralized acid group-containing monomers isreferred to herein as the “degree of neutralization.” The degree ofneutralization will preferably not exceed 98%.

[0247] Hydrogel forming polymeric gelling agents suitable for use hereinare well known in the art, and are described, for example, in U.S. Pat.No. 4,076,663, Masuda et al., issued Feb. 28, 1978; U.S. Pat. No.4,062,817, Westerman, issued Dec. 13, 1977; U.S. Pat. No. 4,286,082,Tsubakimoto et al., issued Aug. 25, 1981; U.S. Pat. No. 5,061,259,Goldman et al., issued Oct. 29, 1991, and U.S. Pat. No. 4,654,039,Brandt et al., issued Mar. 31, 1987 each of which is incorporated hereinin its entirety.

[0248] Hydrogel forming polymeric gelling agents suitable for use hereinare also described in U.S. Pat. No. 4,731,067, Le-Khac, issued Mar. 15,1988, U.S. Pat. No. 4,743,244, Le-Khac, issued May 10, 1988, U.S. Pat.No. 4,813,945, Le-Khac, issued Mar. 21, 1989, U.S. Pat. No. 4,880,868,Le-Khac, issued Nov. 14, 1989, U.S. Pat. No. 4,892,533, Le-Khac, issuedJan. 9, 1990, U.S. Pat. No. 5,026,784, Le-Khac, issued Jun. 25, 1991,U.S. Pat. No. 5,079,306, Le-Khac, issued Jan. 7, 1992, U.S. Pat. No.5,151,465, Le-Khac, issued Sep. 29, 1992, U.S. Pat. No. 4,861,539,Allen, Farrer, and Flesher, issued Aug. 29, 1989, and U.S. Pat. No.4,962,172, Allen, Farrer, and Flesher, issued Oct. 9, 1990, each ofwhich is incorporated herein by reference in its entirety.

[0249] Suitable hydrogel forming polymeric gelling agents in the form ofparticles are commercially available from Hoechst Celanese Corporation,Portsmouth, Va., USA (Sanwet™ Superabsorbent Polymers) Nippon Shokubai,Japan (Aqualic™, e.g., L-75, L-76) and Dow Chemical Company, Midland,Mich., USA (Dry Tech™).

[0250] Hydrogel forming polymeric gelling agents in the form of fibersare commercially available from Camelot Technologies Inc., Leominster,Mass., USA (Fibersorb™, e.g., SA 7200H, SA 7200M, SA 7000L, SA 7000, andSA 7300).

[0251] The articles of the present invention may also contain otherhydrophilic gelling agents. These include carboxylic acid-containingpolymers as otherwise described above, except which have relativelylower degrees of crosslinking, such that they exhibit a Tg below 140°C., as well as a variety of other water soluble or colloidally watersoluble polymers, such as cellulose ethers (e.g. hydroxyethyl cellulose,methyl cellulose, hydroxy propylmethyl cellulose), polyvinylpyrrolidone,polyvinylalcohol, guar gum, hydroxypropyl guar gum and xanthan gum.Preferred among these additional hydrophilic gelling agents are theacid-containing polymers, particularly carboxylic acid-containingpolymers. Especially preferred are those that comprise water-solublepolymer of acrylic acid crosslinked with a polyalkenyl polyether of apolyhydric alcohol, and optionally an acrylate ester or a polyfunctionalvinylidene monomer.

[0252] Preferred copolymers useful in the present invention are polymersof a monomeric mixture containing 95 to 99 weight percent of anolefinically unsaturated carboxylic monomer selected from the groupconsisting of acrylic, methacrylic and ethacrylic acids; about 1 toabout 3.5 weight percent of an acrylate ester of the formula:

[0253] wherein R is an alkyl radical containing 10 to 30 carbon atomsand R₁ is hydrogen, methyl or ethyl; and 0.1 to 0.6 weight percent of apolymerizable cross-linking polyalkenyl polyether of a polyhydricalcohol containing more than one alkenyl ether group per moleculewherein the parent polyhydric alcohol contains at least 3 carbon atomsand at least 3 hydroxyl groups.

[0254] Preferably, these polymers contain from about 96 to about 97.9weight percent of acrylic acid and from about 2.5 to about 3.5 weightpercent of acrylic esters wherein the alkyl group contains 12 to 22carbon atoms, and R₁ is methyl, most preferably the acrylate ester isstearyl methacrylate. Preferably, the amount of crosslinking polyalkenylpolyether monomer is from about 0.2 to 0.4 weight percent. The preferredcrosslinking polyalkenyl polyether monomers are allyl pentaerythritol,trimethylolpropane diallylether or allyl sucrose. These polymers arefully described in U.S. Pat. No. 4,509,949, to Huang et al., issued Apr.5, 1985, this patent being incorporated herein by reference.

[0255] Other preferred copolymers useful in the present invention arethe polymers which contain at least two monomeric ingredients, one beinga monomeric olefinically-unsaturated carboxylic acid, and the otherbeing a polyalkenyl, polyether of a polyhydric alcohol. Additionalmonomeric materials may be present in the monomeric mixture if desired,even in predominant proportion.

[0256] The first monomeric ingredient useful in the production of thesecarboxylic polymers are the olefinically-unsaturated carboxylic acidscontaining at least one activated carbon-to-carbon olefinic double bond,and at least one carboxyl group. The preferred carboxylic monomers arethe acrylic acids having the general structure

[0257] wherein R² is a substituent selected from the class consisting ofhydrogen, halogen, and the cyanogen (—C═N) groups, monovalent alkylradicals, monovalent alkaryl radicals and monovalent cycloaliphaticradicals. Of this class, acrylic, methacrylic, and ethacrylic acid aremost preferred. Another useful carboxylic monomer is maleic anhydride orthe acid. The amount of acid used will be from about 95.5 to about 98.9weight percent.

[0258] The second monomeric ingredient useful in the production of thesecarboxylic polymers are the polyalkenyl polyethers having more than onealkenyl ether grouping per molecule, such as alkenyl groups in which anolefinic double bond is present attached to a terminal methylenegrouping, CH₂═C<.

[0259] The additional monomeric materials which may be present in thepolymers include polyfunctional vinylidene monomers containing at leasttwo terminal CH₂< groups, including for example, butadiene, isoprene,divinyl benzene, divinyl naphthlene, allyl acrylates, and the like.These polymers are fully described in U.S. Pat. No. 2,798,053, to Brown,issued Jul. 2, 1957, which is incorporated herein by reference in itsentirety.

[0260] Examples of carboxylic acid copolymers useful in the presentinvention include Carbomer 934, Carbomer 941, Carbomer 950, Carbomer951, Carbomer 954, Carbomer 980, Carbomer 981, Carbomer 1342,acrylates/C10-30 alkyl acrylate cross polymer (available as Carbopol934, Carbopol 941, Carbopol 950, Carbopol 951, Carbopol 954, Carbopol980, Carbopol 981, Carbopol 1342, and the Pemulen series, respectively,from B. F. Goodrich).

[0261] Other carboxylic acid copolymers useful in the present inventioninclude sodium salts of acrylic acid/acrylamide copolymers sold by theHoechst Celanese Corporation under the trademark of Hostaceren PN73.Also included are the hydrogel polymers sold by Lipo Chemicals Inc.under the trademark of HYPAN hydrogels. These hydrogels consist ofcrystalline plicks of nitrates on a C—C backbone with various otherpendant groups such as carboxyls, amides, and amidines. An example wouldinclude HYPAN SA 100 H, a polymer powder available from Lipo Chemical.

[0262] Neutralizing agents for use in neutralizing the acidic groups ofthese polymers include those previously described.

[0263] Cationic Surfactants

[0264] Cationic surfactants are typically categorized as non-latheringsurfactants but may be used in the articles of the present inventionprovided they do not negatively impact the desired benefits of thearticles.

[0265] Nonlimiting examples of cationic surfactants useful herein aredisclosed in McCutcheon's, Detergents and Emulsifiers, North Americanedition (1986), published by allured Publishing Corporation; andMcCutcheon's, Functional Materials, North American Edition (1992); bothof which are incorporated by reference herein in their entirety.

[0266] Nonlimiting examples of cationic surfactants useful hereininclude cationic alkyl ammonium salts such as those having the formula:

R₁R₂R₃R₄N⁺X⁻

[0267] wherein R₁, is selected from an alkyl group having from about 12to about 18 carbon atoms, or aromatic, aryl or alkaryl groups havingfrom about 12 to about 18 carbon atoms; R₂, R₃, and R₄ are independentlyselected from hydrogen, an alkyl group having from about 1 to about 18carbon atoms, or aromatic, aryl or alkaryl groups having from about 12to about 18 carbon atoms; and X is an anion selected from chloride,bromide, iodide, acetate, phosphate, nitrate, sulfate, methyl sulfate,ethyl sulfate, tosylate, lactate, citrate, glycolate, and mixturesthereof. Additionally, the alkyl groups can also contain ether linkages,or hydroxy or amino group substituents (e.g., the alkyl groups cancontain polyethylene glycol and polypropylene glycol moieties).

[0268] More preferably, R₁ is an alkyl group having from about 12 toabout 18 carbon atoms; R₂ is selected from H or an alkyl group havingfrom about 1 to about 18 carbon atoms; R₃ and R₄ are independentlyselected from H or an alkyl group having from about 1 to about 3 carbonatoms; and X is as described in the previous paragraph.

[0269] Most preferably, R₁ is an alkyl group having from about 12 toabout 18 carbon atoms; R₂, R₃, and R₄ are selected from H or an alkylgroup having from about 1 to about 3 carbon atoms; and X is as describedpreviously.

[0270] Alternatively, other useful cationic surfactants includeamino-amides, wherein in the above structure R₁ is alternativelyR₅CO—(CH₂)_(n)—, wherein R₅ is an alkyl group having from about 12 toabout 22 carbon atoms, and n is an integer from about 2 to about 6, morepreferably from about 2 to about 4, and most preferably from about 2 toabout 3. Nonlimiting examples of these cationic emulsifiers includestearamidopropyl PG-dimonium chloride phosphate, stearamidopropylethyldimonium ethosulfate, stearamidopropyl dimethyl (myristyl acetate)ammonium chloride, stearamidopropyl dimethyl cetearyl ammonium tosylate,stearamidopropyl dimethyl ammonium chloride, stearamidopropyl dimethylammonium lactate, and mixtures thereof.

[0271] Nonlimiting examples of quaternary ammonium salt cationicsurfactants include those selected from the group consisting of cetylammonium chloride, cetyl ammonium bromide, lauryl ammonium chloride,lauryl ammonium bromide, stearyl ammonium chloride, stearyl ammoniumbromide, cetyl dimethyl ammonium chloride, cetyl dimethyl ammoniumbromide, lauryl dimethyl ammonium chloride, lauryl dimethyl ammoniumbromide, stearyl dimethyl ammonium chloride, stearyl dimethyl ammoniumbromide, cetyl trimethyl ammonium chloride, cetyl trimethyl ammoniumbromide, lauryl trimethyl ammonium chloride, lauryl trimethyl ammoniumbromide, stearyl trimethyl ammonium chloride, stearyl trimethyl ammoniumbromide, lauryl dimethyl ammonium chloride, stearyl dimethyl cetylditallow dimethyl ammonium chloride, dicetyl ammonium chloride, dicetylammonium bromide, dilauryl ammonium chloride, dilauryl ammonium bromide,distearyl ammonium chloride, distearyl ammonium bromide, dicetyl methylammonium chloride, dicetyl methyl ammonium bromide, dilauryl methylammonium chloride, dilauryl methyl ammonium bromide, distearyl methylammonium chloride, distearyl dimethyl ammonium chloride, distearylmethyl ammonium bromide, and mixtures thereof. Additional quaternaryammonium salts include those wherein the C12 to C22 alkyl carbon chainis derived from a tallow fatty acid or from a coconut fatty acid. Theterm “tallow” refers to an alkyl group derived from tallow fatty acids(usually hydrogenated tallow fatty acids), which generally have mixturesof alkyl chains in the C16 to C18 range. The term “coconut” refers to analkyl group derived from a coconut fatty acid, which generally havemixtures of alkyl chains in the C12 to C14 range. Examples of quaternaryammonium salts derived from these tallow and coconut sources includeditallow dimethyl ammonium chloride, ditallow dimethyl ammonium methylsulfate, di(hydrogenated tallow) dimethyl ammonium chloride,di(hydrogenated tallow) dimethyl ammonium acetate, ditallow dipropylammonium phosphate, ditallow dimethyl ammonium nitrate,di(coconutalkyl)dimethyl ammonium chloride, di(coconutalkyl)dimethylammonium bromide, tallow ammonium chloride, coconut ammonium chloride,stearamidopropyl PG-dimonium chloride phosphate, stearamidopropylethyldimonium ethosulfate, stearamidopropyl dimethyl (myristyl acetate)ammonium chloride, stearamidopropyl dimethyl cetearyl ammonium tosylate,stearamidopropyl dimethyl ammonium chloride, stearamidopropyl dimethylammonium lactate, and mixtures thereof.

[0272] Preferred cationic surfactants useful herein include thoseselected from the group consisting of dilauryl dimethyl ammoniumchloride, distearyl dimethyl ammonium chloride, dimyristyl dimethylammonium chloride, dipalmityl dimethyl ammonium chloride, distearyldimethyl ammonium chloride, and mixtures thereof.

[0273] Chelators

[0274] The articles of the present invention may also comprise a safeand effective amount of a chelator or chelating agent. As used herein,“chelator” or “chelating agent” means an active agent capable ofremoving a metal ion from a system by forming a complex so that themetal ion cannot readily participate in or catalyze chemical reactions.The inclusion of a chelating agent is especially useful for providingprotection against UV radiation that can contribute to excessive scalingor skin texture changes and against other environmental agents, whichcan cause skin damage.

[0275] A safe and effective amount of a chelating agent may be added tothe compositions of the subject invention, preferably from about 0.1% toabout 10%, more preferably from about 1% to about 5%, of thecomposition. Exemplary chelators that are useful herein are disclosed inU.S. Pat. No. 5,487,884, issued Jan. 30, 1996 to Bissett et al.;International Publication No. 91/16035, Bush et al., published Oct. 31,1995; and International Publication No. 91/16034, Bush et al., publishedOct. 31, 1995. Preferred chelators useful in compositions of the subjectinvention are furildioxime and derivatives thereof.

[0276] Flavonoids

[0277] The articles of the present invention may optionally comprise aflavonoid compound. Flavonoids are broadly disclosed in U.S. Pat. Nos.5,686,082 and 5,686,367, both of which are herein incorporated byreference. Flavonoids suitable for use in the present invention areflavanones selected from the group consisting of unsubstitutedflavanones, mono-substituted flavanones, and mixtures thereof; chalconesselected from the group consisting of unsubstituted chalcones,mono-substituted chalcones, di-substituted chalcones, tri-substitutedchalcones, and mixtures thereof; flavones selected from the groupconsisting of unsubstituted flavones, mono-substituted flavones,di-substituted flavones, and mixtures thereof; one or more isoflavones;coumarins selected from the group consisting of unsubstituted coumarins,mono-substituted coumarins, di-substituted coumarins, and mixturesthereof; chromones selected from the group consisting of unsubstitutedchromones, mono-substituted chromones, di-substituted chromones, andmixtures thereof; one or more dicoumarols; one or more chromanones; oneor more chromanols; isomers (e.g., cis/trans isomers) thereof; andmixtures thereof. By the term “substituted” as used herein meansflavonoids wherein one or more hydrogen atom of the flavonoid has beenindependently replaced with hydroxyl, C1-C8 alkyl, C1-C4 alkoxyl,O-glycoside, and the like or a mixture of these substituents.

[0278] Examples of suitable flavonoids include, but are not limited to,unsubstituted flavanone, mono-hydroxy flavanones (e.g., 2′-hydroxyflavanone, 6-hydroxy flavanone, 7-hydroxy flavanone, etc.), mono-alkoxyflavanones (e.g., 5-methoxy flavanone, 6-methoxy flavanone, 7-methoxyflavanone, 4′-methoxy flavanone, etc.), unsubstituted chalcone(especially unsubstituted trans-chalcone), mono-hydroxy chalcones (e.g.,2′-hydroxy chalcone, 4′-hydroxy chalcone, etc.), di-hydroxy chalcones(e.g., 2′, 4-dihydroxy chalcone, 2′, 4′-dihydroxy chalcone,2,2′-dihydroxy chalcone, 2′,3-dihydroxy chalcone, 2′, 5′-dihydroxychalcone, etc.), and tri-hydroxy chalcones (e.g., 2′, 3′, 4′-trihydroxychalcone, 4,2′, 4′-trihydroxy chalcone, 2,2′, 4′-trihydroxy chalcone,etc.), unsubstituted flavone, 7,2′-dihydroxy flavone, 3′, 4′-dihydroxynaphthoflavone, 4′-hydroxy flavone, 5,6-benzoflavone, and7,8-benzoflavone, unsubstituted isoflavone, daidzein (7,4′-dihydroxyisoflavone), 5,7-dihydroxy-4′-methoxy isoflavone, soy isoflavones (amixture extracted from soy), unsubstituted coumarin, 4-hydroxy coumarin,7-hydroxy coumarin, 6-hydroxy-4-methyl coumarin, unsubstituted chromone,3-formyl chromone, 3-formyl-6-isopropyl chromone, unsubstituteddicoumarol, unsubstituted chromanone, unsubstituted chromanol, andmixtures thereof.

[0279] Preferred for use herein are unsubstituted flavanone, methoxyflavanones, unsubstituted chalcone, 2′, 4-dihydroxy chalcone, andmixtures thereof. Most preferred are unsubstituted flavanone,unsubstituted chalcone (especially the trans isomer), and mixturesthereof.

[0280] They can be synthetic materials or obtained as extracts fromnatural sources (e.g., plants). The naturally sourced material can alsofurther be derivatized (e.g., a glycoside, an ester or an etherderivative prepared following extraction from a natural source).Flavonoid compounds useful herein are commercially available from anumber of sources, e.g., Indofine Chemical Company, Inc. (Somerville,N.J.), Steraloids, Inc. (Wilton, N.H.), and Aldrich Chemical Company,Inc. (Milwaukee, Wis.).

[0281] Mixtures of the above flavonoid compounds may also be used.

[0282] The herein described flavonoid compounds are preferably presentin the instant invention at concentrations of from about 0.01% to about20%, more preferably from about 0.1% to about 10%, and most preferablyfrom about 0.5% to about 5%.

[0283] Sterols

[0284] The articles of the present invention may comprise a safe andeffective amount of one or more sterol compounds. Examples of usefulsterol compounds include sitosterol, stigmasterol, campesterol,brassicasterol, lanosterol, 7-dehydrocholesterol, and mixtures thereof.These can be synthetic in origin or from natural sources, e.g., blendsextracted from plant sources (e.g., phytosterols).

[0285] Anti-Cellulite Agents

[0286] The articles of the present invention may also comprise a safeand effective amount of an anti-cellulite agent. Suitable agents mayinclude, but are not limited to, xanthine compounds (e.g., caffeine,theophylline, theobromine, and aminophylline).

[0287] Skin Lightening Agents

[0288] The articles of the present invention may comprise a skinlightening agent. When used, the compositions preferably comprise fromabout 0.1% to about 10%, more preferably from about 0.2% to about 5%,also preferably from about 0.5% to about 2%, by weight of thecomposition, of a skin lightening agent. Suitable skin lightening agentsinclude those known in the art, including kojic acid, arbutin, ascorbicacid and derivatives thereof, e.g., magnesium ascorbyl phosphate orsodium ascorbyl phosphate or other salts of ascorbyl phosphate. Skinlightening agents suitable for use herein also include those describedin copending patent application Ser. No. 08/479,935, filed on Jun. 7,1995 in the name of Hillebrand, corresponding to PCT application Ser.No. 95/07,432, filed Jun. 12, 1995; and copending patent applicationSer. No. 08/390,152, filed on Feb. 24, 1995 in the names of Kalla L.Kvalnes, Mitchell A. DeLong, Barton J. Bradbury, Curtis B. Motley, andJohn D. Carter, corresponding to PCT application Ser. No. 95/02,809,filed Mar. 1, 1995, published Sep. 8, 1995.

[0289] Binders

[0290] The articles of the present invention may optionally comprisebinders. Binders or binding materials are useful for sealing the variouslayers of the present articles to one another thereby maintaining theintegrity of the article. The binders may be in a variety of formsincluding, but not limited to, spray on, webs, separate layers, bindingfibers, etc. Suitable binders may comprise latexes, polyamides,polyesters, polyolefins and combinations thereof.

[0291] Additional Layers

[0292] In another embodiment, the article of the present invention maycomprise one or more additional layers which one having ordinary skillin the art would recognize as separate and distinct from the batting andnonwoven layers yet which are attached to the batting and nonwovenlayers at some point. The additional layers are suitable for enhancingthe overall grippability of the side of the article closest to the handor other means for exerting mechanical action on the surface to becleansed and/or therapeutically treated. Also, the additional layers aresuitable for enhancing the soft feel of the side of the article whichcontacts the area to be cleansed and/or therapeutically treated. In anyinstance, these additional layers may also be referred to asconsecutively numbered layers in addition to the two essential layers ofthe articles of the present invention, e.g., third layer, fourth layer,etc.

[0293] Suitable additional layers may be macroscopically expanded. Asused herein, “macroscopically expanded, refers to webs, ribbons, andfilms which have been caused to conform to the surface of athree-dimensional forming structure so that both surfaces thereofexhibit a three-dimensional forming pattern of surface aberrationscorresponding to the macroscopic cross-section of the forming structure,wherein the surface aberrations comprising the pattern are individuallydiscernible to the normal naked eye (i.e., normal naked eye having 20/20vision) when the perpendicular distance between the viewer's eye and theplane of the web is about 12 inches.

[0294] As used herein, “embossed” it is meant that the forming structureof the material exhibits a pattern comprised primarily of maleprojections. On the other hand, “debossed” refers to when the formingstructure of the material exhibits a pattern comprised primarily offemale capillary networks.

[0295] Preferred macroscopically expanded films comprise formed filmswhich are structural elastic-like films. These films are described inU.S. Pat. No. 5,554,145, issued Sep. 10, 1996, to Roe et al., which isincorporated by reference herein in its entirety.

[0296] Materials suitable for use in the additional layer having athickness of at least one millimeter include, but are not limited to,those web materials disclosed in U.S. Pat. No. 5,518,801, issued toChappell et al. on May 21, 1996, which is incorporated by referenceherein in its entirety.

[0297] Methods of Manufacture

[0298] The personal care articles of the present invention aremanufactured by adding the cleansing component and/or the therapeuticbenefit component to the appropriate sheet of the batting layer ornonwoven layer via a conventional method which may include, but is notlimited to, sprinkling, dip coating, spraying, slot coating, and rolltransfer (e.g., pressure roll or kiss roll). The sheet of the remaininglayer is then placed on the sheet of the first layer, preferably, butnot always, over the cleansing component and/or therapeutic benefitcomponent. The sheets are sealed together by a conventional sealingmethod which may include, but is not limited to, heat, pressure, glue,ultrasound, etc. Heat sealing devices vary in design, and where a sealmay not be able to be effected an interposing layer of a low-meltingheat-sealable fibrous web such as the polyamide fibrous web known asWonder Under (manufactured by Pellon, available from H. Levinson & Co.,Chicago, Ill.) may be used between layers for this and other exampleswithout changing the effect or utility of the articles. The sealedsheets are then partitioned into units for the consumer's use. Optionalmanufacturing steps may include calendaring to flatten the article,drying, creping, shrinking, stretching, or otherwise mechanicallydeforming.

[0299] Methods of Cleansing and Delivering a Therapeutic or AestheticBenefit Agent to the Skin or Hair

[0300] The present invention also relates to a method of cleansing theskin or hair with a personal care article of the present invention.These methods comprise the steps of: a) wetting with water asubstantially dry, disposable personal care article comprising: 1) awater insoluble substrate comprising: a lofty, low-density batting layercomprising synthetic fibers wherein said batting layer is non-scouring;and a non-lofty, fluid-permeable nonwoven layer which is disposedadjacent to said batting layer; and 2) a cleansing component disposedadjacent to said water insoluble substrate, wherein said componentcomprises from about 10% to about 1000%, by weight of the waterinsoluble substrate, of a lathering surfactant; and b) contacting theskin or hair with the wetted article.

[0301] In another embodiment, the present invention is useful fordelivering a therapeutic benefit component to the area in need oftreatment (e.g., skin, hair, etc.) wherein the method comprises theadditional steps of: A) wetting with water a substantially dry,disposable personal care article, said article comprising: 1) a waterinsoluble substrate which comprises (a) a non-scouring, lofty,low-density batting layer comprising synthetic fibers; and (b) anon-lofty, fluid-permeable nonwoven layer which is disposed adjacent tosaid batting layer; and 2) a therapeutic benefit component, disposedadjacent to said water insoluble substrate, wherein said componentcomprises from about 10% to about 1000%, by weight of the waterinsoluble substrate, of a therapeutic benefit agent; and B) contactingthe skin or hair with the wetted article.

[0302] The articles of the present invention are water-activated and aretherefore intended to be wetted with water prior to use. As used herein,“water-activated” means that the present invention is presented to theconsumer in dry form to be used after wetting with water. It is foundthat when the articles of the present invention include a latheringsurfactant they produce a lather or are “activated” upon contact withwater and further agitation. Accordingly, the article is wetted byimmersion in water or by placing it under a stream of water. When thearticles of the present invention comprise a lathering surfactant in thecleansing component, lather may be generated from the article bymechanically agitating and/or deforming the article either prior to orduring contact of the article with the skin or hair. The resultinglather is useful for cleansing the skin or hair. During the cleansingprocess and subsequent rinsing with water, any therapeutic or aestheticbenefit agents are deposited onto the skin or hair. Deposition of thetherapeutic or aesthetic benefit agents are enhanced by the physicalcontact of the substrate with the skin or hair as well by the inclusionof one or more deposition aids.

EXAMPLES

[0303] The following examples further describe and demonstrateembodiments within the scope of the present invention. In the followingexamples, all ingredients are listed at an active level. The examplesare given solely for the purpose of illustration and are not to beconstrued as limitations of the present invention, as many variationsthereof are possible without departing from the spirit and scope of theinvention.

[0304] Ingredients are identified by chemical or CTFA name.

[0305] I. Cleansing Components

Example 1

[0306] Prepare a representative cleansing component for the articles ofthe present invention in the following manner.

[0307] Shave a 53.0 gms of a bar soap which includes the followingcomponents: Component Wt % Sodium Cocyl Isethionate 27.77 Paraffin 16.72Sodium Alkyl Glycerol Sulfonate (AGS) 14.90 Soaps 11.41 Glycerine 8.57Water 5.50 Stearic Acid 5.74 Sodium Isethionate 3.04 NaCl 1.41 EDTA 0.10Etidronic Acid 0.10 Polyox 0.03 Perfume 0.70 Miscellaneous (includingpigments) 4.01 Total 100

[0308] Mix the bar soap shavings with 37.0 gms glycerin (99.7%), 9.5 gmswater, and 0.5 gms perfume. Heat mixture to 200° F. while stirringcontinuously. Cold-mill mixture on a standard 3-roll mill and storecleansing component in a suitable sealed container.

Example 2

[0309] Prepare a representative cleansing component for the articles ofthe present invention in the following manner.

[0310] Shave 40.0 gms of a bar soap which includes the followingcomponents: Component Wt % Sodium Soap 52.40 Sodium Alkyl GlycerolSulfonate (AGS) 16.50 Magnesium Soap 13.40 Glycerine 0.19 Water 5.50Stearic Acid 1.60 Sodium Isethionate 3.00 NaCl 3.89 EDTA 0.10 EtidronicAcid 0.10 Perfume 0.70 Miscellaneous (including pigments) 2.62 Total 100

[0311] Mix the bar soap shavings with 45.0 gms glycerin (99.7%), 4.5 gmswater, and 0.5 gms perfume. Heat mixture to 200° F. while stirringcontinuously. Cold-mill mixture on a standard 3-roll mill and storecleansing component in a suitable sealed container.

Example 3

[0312] A representative powdery cleansing component for the articles ofthe present invention is prepared in the following manner.

[0313] Shave 40.0 gms of a bar soap which includes the followingcomponents: Component Wt % Soap (Magnesium and Sodium) 80.16 Water 11.50Stearic Acid 5.70 NaCl 1.10 EDTA 0.25 Perfume 1.15 Miscellaneous(including pigments) 0.14 Total 100

[0314] Store the bar soap flakes in a suitable sealed container.

Example 4

[0315] A representative powdery cleansing component for the articles ofthe present invention is prepared in the following manner.

[0316] Shave 40.0 gms of a bar soap which includes the followingcomponents: Component Wt % Soap (Magnesium and Sodium) 80.16 Water 11.50Stearic Acid 5.70 NaCl 1.10 EDTA 0.25 Perfume 1.15 Miscellaneous(including pigments) 0.14 Total 100

[0317] Blend the bar soap flakes with sodium bicarbonate in a 90:10weight ratio. Mill the mixture twice in a standard 3-roll mill. Collectthe flakes and store in a suitable sealed container.

Example 5

[0318] Prepare a representative cleansing component for the articles ofthe present invention in the following manner. Blend the cleansingcomponent of Example 2 with 0.1% by weight of the bar soap flakes of aprotease enzyme. Next, blend the resultant mixture with 2% by weight ofthe cleansing component of a dry hydrocolloid, sodiumcarboxymethylcellulose, and mill. Store the enzyme cleansing componentin a suitable sealed container.

Example 6

[0319] Prepare a representative liquid cleansing component whichincludes the following components. Component Wt % Sodium coconut alkylglyceryl sulfonate (AGS) 7.2 Ammonium lauryl sulfate (ALS) 10.4 Alkyllaureth sulfate (AE3S) 10.4 Poly(ethylene oxide) (PolyOx WSR N-3000, 0.5Union Carbide) Xanthan gum 1.4 Water 70.1

Example 7

[0320] Prepare a representative cleansing component for the articles ofthe present invention in the following manner. Heat 3 lbs of soapshavings of Example 2 with ¾ cup of isopropyl alcohol (99%) until thesoap is melted. When the soap has melted, add the remaining alcohol. Add10 oz. table sugar dissolved in as little water as possible. Blend about4 tsp. of a dye into 8 oz. glycerin. Add the glycerin (99.7%). Stir.Continue to heat until consistency changes from a thin liquid torope-like ribbons falling off the stirring implement and an aliquot ofmaterial hardens when dropped on a cold surface. Pour the mixture into asuitable container to harden. The mixture has the advantage of beingremeltable upon heating which allows easy processing to preparearticles.

Example 8

[0321] Prepare a representative tear-free liquid cleansing componentwhich includes the following components. Component Wt % Cocamido propylbetaine 17.1 Sodium trideceth sulfate 8.3 POE 100 sorbitan monooleate7.5 Misc. (including perfume, preservative, dye) 2.0 Water 65.1

[0322] Distinguishing characteristics of this composition are itsnon-irritating properties to skin and eyes.

Example 9

[0323] Prepare a representative liquid cleansing component whichincludes the following components. Component Wt % Polyquaternium 10 0.50Sodium Lauroamphoacetate 5.4 Sodium Laureth 3 Sulfate 11.6 Disodium EDTA0.20 Sodium citrate dihydrate 0.50 Citric acid, anhydrous 1.0 PEG-6caprylic/capric glycerides 2.0 Cocamide MEA 2.0 Glycerin 3.5 MgSO4-7H2O(Epsom salts) 1.5 Maleated Soybean Oil 2.5 Deodorized Soybean Oil 5.0Misc. (including perfume, caustic, colorant) 1.5 Water 62.8

[0324] The mixture is mild for use on sensitive skin.

Example 10

[0325] Prepare a representative liquid cleansing component whichincludes the following components. Component Wt % Polyquaternium-10 0.1Sodium sulfate 1.5 Lauryl alcohol 0.3 Sodium laureth sulfate 5.8 Citricacid, anhydrous 0.2 Cocamidopropyl betaine 15.5 Sodium lauroylsarcosinate 1.5 Misc. (including perfume, blue colorant) 1.0 Water 74.1

Example 11

[0326] Prepare a representative cleansing component which includes thefollowing components. Component Wt % Decylpolyglucose 12.0Cocamidopropyl betaine 12.0 Sodium lauroyl sarcosinate 12.0 Butyleneglycol 3.6 PEG 14M 1.8 Polyquaternium-10 0.9 Dex panthenol 0.7Phenoxyethanol 0.5 Benzyl alcohol 0.5 Methylparaben 0.45 Propylparaben0.25 Disodium EDTA 0.2 Water 55.1

Example 12

[0327] Prepare a representative cleansing component which includes thefollowing components. Component Wt % EGDS 3.1 Cocamidopropyl betaine 4.0TEA soap (Molecular Weight about 330) 9.5 Monoalkyl phosphate 15.0Cocamine oxide 7.5 1,2-propanediol 1.0 Ethanol 3.0 Miscellaneous(perfume, colorant, preservative) 8.9 Water 48.0

[0328] Heat the mixture to 50 degrees Celsius, stirring continuously,until the mixture has lost 38% of its original weight, and it has apaste-like consistency. The cleansing component advantageously is easyto process with substrate layers and requires no further drying.

Example 13

[0329] Prepare a representative cleansing component which includes thefollowing components. Component Wt % SEFA* Cottonate 57.5 Citric acid0.30 Cocamidopropyl betaine 3.5 Sodium lauroyl sarcosinate 10.7 Ethylenevinyl acetate polymer (Elvax 40W) 8.0 Silicone polymer microbeads(Tospearly 145A) 20.0

[0330] Melt the ethylene vinyl acetate polymer into the SEFA cottonateat 90 degrees Celsius and high shear mix. Add the surfactant powders andcitric acid and mix. Add the silicone polymer microbeads, mix, and coolto set. The composition is remeltable and easy impregnates into or coatonto cloths.

Example 14

[0331] Prepare a representative cleansing component which includes thefollowing components. Component Wt % Sodium laureth-10 carboxylate(Empicol CB5S*) 50.0 C12-14, 12EO Alcohol Ethoxylate (Empilan 50.0KB12*)

[0332] Melt the alcohol ethoxylate, blend in the carboxylate untilhomogeneous, cool to solidify until ready for use. The composition isremeltable and easy impregnate into or coat onto cloths.

Example 15

[0333] Prepare a representative cleansing component which includes thefollowing components. Component Wt % Monosodium lauroyl glutamate 22.0Cocamidopropyl betaine 2.0 Sodium chloride 1.0 Glycerin 2.5 Water 72.5

[0334] Heat the components together with gentle stirring untilhomogeneous.

Example 16

[0335] Prepare a representative cleansing component which includes thefollowing components. Component Wt % Triethanolamine 2.9Polyquaternium-39 0.1 Monolauryl phosphate 4.0 C12-C14N-methyl Glucoseamide¹ 5.0 Cocamidopropylhydroxysultaine² 2.0 Sodium decyl sulfate 0.5Citric acid monohydrate 0.3 Perfume, Preservatives & misc. 4.0 Water81.2

[0336] Add ingredients slowly in the following order at 60° C. untileach is dissolved in the water: TEA, lauryl phosphate, glucose amide.Cool to 45° C. and add sultaine, polyquaternium-39 and sulfate, stirringas before. Add perfume, preservatives and cool to room temperature.

Example 17

[0337] Prepare a representative cleansing component by mixing thefollowing components. Component Wt % Lauroyl polyglucose¹ 20.0Cetyltrimethylammonium bromide 4.0 Perfume, Preservatives & misc. 4.0Water 72.0

[0338] II. Therapeutic Benefit Components

Examples 18-22

[0339] Prepare a representative skin conditioning component by mixingthe following components. Exam- Example Example Example Example pleComponent 18 19 20 21 22 SEFA* 48.0 75.0 33.5 40.0 80.0 Cottonate SEFA*12.0 25.0 8.4 10.0 10.0 Behenate Petrolatum 10.0 — 7.0 — — Glyceryl 5.0— 3.5 — — Tribehenate Stearyl Alcohol — — — 5.0 — Paraffin — — — 15.0 —Cholesterol 25.0 — 17.5 — — Ester Ozokerite Wax — — — — 10.0 Glycerin —— 28.0 — — Triglyceryl — — 1.9 — — monostearate Decaglyceryl — — 0.2 — —dipalmitate Nonylphenol — — — 30.0 — polyglycine ether¹

Examples 23-27

[0340] Prepare a representative skin conditioning component by mixingthe following components. Example Example Example Example ExampleComponent 23 24 25 26 27 Petrolatum (white) 35.87 35.87 — — 34.0 Mineraloil 11.0 13.0 — — 10.0 Jojoba oil — — — 4.5 Castor oil 10.0 9.0 — —Cocoa butter 5.0 Diisostearyl 20.0 20.0 — — trimethylpopane siloxysilicate Polydimethylsiloxane, — — 0.7 1.5 500 cSt fluidDecamethylcyclopentasiloxane — — — 16.5 Octamethylcyclotetra — — — 10.0siloxane Polydimethylsiloxane, — — 5.9 7.5 gum Stearyl methicone — — —3.0 wax Polybutene — — — 4.5 Candelilla wax 4.6 4.6 — — 6.0 Paraffin wax— — — 15.0 2.0 Microcrystalline — — — 6.0 4.0 wax Beeswax 3.0 3.0 — —4.0 Ozokerite wax 6.0 6.0 — — Carnauba wax 3.0 3.0 — — Hydrogenatedcastor 0.50 0.50 4.0 — oil Silica — — — 4.5 Sodium magnesium — — — 1.5silicate Tocopherol 0.03 0.03 — — Cyclomethicone — — 59.0 — Stearylalcohol — — 25.5 — 9.0 Cetyl alcohol 9.0 Glyceryl stearate — — 2.6 —Acetylated 15.0 monoglyceride Diisostearyl — — — 6.0 maleate¹ Glyceryldistearate — — — 9.5 Glycerin — — — 6.0 Water — — — 3.0 Nonylphenol — —5.0 — polyglycine ether² Micronized titanium 5.0 — — dioxide Octyl 5.0 —— — methoxycinnamate Fragrance & misc. 1.0 1.0 1.0 1.0 2.0

Example 28

[0341] Prepare a representative skin conditioning component by mixingthe following components. Component Example 28 Polydecene¹ 53.3 StearylAlcohol 7.7 12-Hydroxystearic acid 13.5 Nonylphenol polyglycine 25.0ether Octyl methoxycinnamate 1.5

Examples 29-31

[0342] Prepare a representative skin conditioning component by mixingthe following components. Component Example 29 Example 30 Example 31Glycerin 95.0 95.0 94.0 Decaglyceryl dipalmitate¹ 5.0 1.0 5.0Deceglyceryl dibehenate 4.0 Tribehenin 1.0

Examples 32-36

[0343] Prepare a representative conditioning component for the articlesof the present invention in the following manner. Exam- Exam- Exam-Exam- ple ple ple ple Example Component 32 33 34 35 36 HydrophobicPhase: SEFA* cottonate 4.65 4.65 15.5 15.5 SEFA* behenate 0.35 0.35 8.08.0 Tribehenin 6.0 6.0 Petrolatum 4.0 4.0 4.4 Cocoa butter 15.5 C10-C3013.0 13.0 Cholesterol/Lanosterol esters C30-C45 alkylmethicone¹Polyglyceryl-4 5.0 5.0 isostearate (and) Cetyl dimethicone (and) Hexyllaurate² PEG 30 3.0 dipolyhydroxystearate³ Tetraglyceryl 2.1monostearate Decaglyceryl 0.90 dipalmitate Ceresin wax 5.5 Beeswax 7.0Lecithin, purified 10.0 1-Monostearin 10.0 Hydrophilic Phase: Glycerin70.0 66.5 42.30 42.30 40.0 Water 3.5 5.0 PVM/MA decadiene 0.25 0.25crosspolymer⁴ Sodium hydroxide 0.25 0.25 (10% solution) Gelatin 2.6Active skin care ingredients: Panthenol 20.0 10.0 2.50 Nicotinamide 5.02.50 3.0 Urea 5.0 2.50 2.50 Allantoin 0.20 0.20 Acetamidopropyl 2.0trimonium chloride

[0344] Process for all emulsions:

[0345] Heat the hydrophobic phase to 70° C., add the hydrophobic activeskin care ingredients, and stir until homogenous. Premix the hydrophilicphase ingredients with the hydrophilic active skin care ingredients,heating gently if necessary to dissolve or disperse them. Add theseslowly to the hydrophobic phase, continuing to stir. Homogenize (highshear mixer; ultrasonic homogenizer; or high pressure homogenizer suchas Microfluidizer from Microfluidics Corp.). Apply immediately tosubstrate surface or cool rapidly to below room temperature in ice orice water. Store in controlled environment, under nitrogen if needed forchemical stability.

Examples 37-41

[0346] Prepare a representative conditioning component as described inExamples 32-36 using the following ingredients. Exam- Exam- ple pleExample Example Example Component 37 38 39 40 41 Hydrophobic Phase:SEFA* cottonate 15.0 16.0 SEFA* behenate 7.5 4.0 Tribehenin 6.0Petrolatum 4.0 4.0 4.4 Cocoa butter 15.5 Polydecene¹ 50.0 46.5 C10-C3013.0 10.5 Cholesterol/ Lanosterol esters PEG 30 3.0 3.0 dipolyhydroxy-stearate Ceresin wax 5.5 Beeswax 7.0 Aluminum/ 7.5 magnesiumhydroxystearate in mineral oil² C30-38 2.5 Olefin/isopropyl maleatecopolymer³ Polyethylene 1.0 wax⁴ Lecithin, purified 10.0 Fragrance and1.0 misc. 1-Monostearin 10.0 Hydrophilic Phase: Glycerin 30.0 25.0 34.8020.0 38.0 Water 8.0 8.0 5.0 PEG 2000 17.0 PVM/MA 0.25 decadienecrosspolymer Sodium 0.25 hydroxide (10% solution) Gelatin 9.50 9.50 2.6Active skin care ingredients: Nicotinamide 2.50 Menthol in 50% 2.50 betacyclodextrin Ascorbic acid 2.50 (natural) Tocopherol 1.00 2.50 (natural)Sorbitol 2.50 Lactic acid 2.5 Urea 2.50 Allantoin 0.20 Triclosan 1.50Chlorhexidine 0.50 Benzoyl peroxide 5.0 15% Salicylic 12.0 acid in PPG14 butyl ether Salicylic acid 2.5

Examples 42-46

[0347] Prepare a representative conditioning component as described inExamples 32-36 using the following ingredients. Exam- Exam- Exam- pleple ple Example Example Component 42 43 44 45 46 Hydrophobic Phase:SEFA* cottonate 20.5 15.5 16.0 Mineral oil 7.50 SEFA* behenate 8.0 8.08.0 Tribehenin 9.5 6.0 6.0 Petrolatum (white 4.0 4.0 22.6 3.0 4.0 orsuperwhite) Candelilla wax 4.50 Paraffin wax 3.00 14.0 Microcrystalline1.50 wax Beeswax 3.00 C10-C30 18.0 13.0 13.0 Cholesterol/Lanost erolesters Laurylmethicone 5.0 copolyol¹ Acetylated 11.3 monoglyceride²Stearyl alcohol 6.8 Cetyl alcohol 6.8 Stearic acid PEG 30 4.5 3.0dipolyhydroxy- stearate Decaglyceryl 0.90 dipalmitate³ Tetraglyceryl2.10 monostearate Fragrance, misc. 1.0 3.0 2.0 Hydrophilic Phase:Glycerin 22.8 27.5 25.0 38.0 41.0 Decaglyceryl 2.5 dipalmitate³ Calciumsilicate 15.0 microspheres⁴ Active skin care ingredients: Guar 1.00hydroxypropyl- trimonium chloride Chitosan glycolate 2.50 Nicotinamide1.50 2.50 2.50 0.2% Carbopol 940 38.0 aqueous solution, pH 6.0 Retinol2.50 Phytantriol⁵ 1.00 Urea 2.50 3.0 2.50 Vitamin C 2.50 Borage oil 2.50Ascorbyl palmitate 1.50 Acetamidopropyl 2.50 trimonium chloride⁶

Example 43

[0348] Glycerin incorporated into microspheres, then blended into moltenlipid phase and cooled for storage or applied to substrate.

Examples 47-52

[0349] Prepare a representative conditioning component as described inExamples 32-36 using the following ingredients. Example Example ExampleExample Example Example Component 47 48 49 50 51 52 Hydrophobic Phase:SEFA* 16.0 16.0 16.0 16.0 16.0 16.0 cottonate Mineral oil SEFA* 8.0 8.08.0 8.0 8.0 behenate Tribehenin 6.0 6.0 6.0 6.0 6.0 6.0 Petrolatum 4.04.0 4.0 4.0 4.0 4.0 (white or superwhite) C10-C30 13.0 13.0 13.0 13.013.0 13.0 Cholesterol/ Lanosterol esters Stearyl 2.0 dimethiconeDimethicone 4.0 hydroxystearate Dimethicone 2.0 copolyol behenate PEG 303.00 3.00 dipolyhydroxy stearate Sodium lauroyl 2.00 glutamate Sodium2.00 stearoyl lactylate Calcium 5.0 stearate Decaglyceryl 0.90 0.90 0.900.90 dipalmitate Tetraglyceryl 2.10 2.10 2.10 2.10 monostearateFragrance, 1.00 1.00 1.00 1.00 1.00 1.00 misc. Hydrophilic Phase:Glycerin 44.5 42.5 35.5 35.5 25.0 43.0 75% 4.50 4.50 Polyethyleneimine¹in water, pH 6.5 Water 2.0 Decaglyceryl 2.50 2.50 dipalmitate Fumedsilica 20.0 Propylene 2.0 glycol alginate² Active skin care ingredients:Nicotinamide 2.00 2.00 Chitosan 1.50 Green tea 4.50 extract Aloe veragel 3.0 Vitamin C 2.50 Ascorbyl 2.00 2.50 palmitate Acetamidopropyl 2.002.00 trimonium chloride

Examples 53-55

[0350] Prepare a representative conditioning component for the articlesof the present invention in the following manner. Component Example 53Example 54 Example 55 Hydrophobic Phase: Lecithin, purified¹ 15.4 10.310.8 Decane 28.6 19.2 15.0 Mineral Oil 5.0 Tricontanyl PVP² 26.0 Stearylalcohol 13.0 12-hydroxystearic acid 19.4 Hydrophilic Phase: Glycerin28.0 18.8 19.6 Propylene glycol 28.0 18.8 19.6 Active skin careingredients: Triclosan 0.20 Salicylic acid 0.40 Nicotinamide 4.0

[0351] Stir all ingredients together until microemulsion forms. Add skincare ingredients first to the phase which most closely matches theirsolubility parameter. When adding waxes, heat slowly just to the waxmelting point, disperse by stirring, and add to substrate or cool toroom temperature and store.

Examples 56-58

[0352] Prepare a representative conditioning component for the articlesof the present invention in the following manner. Component Example 56Example 57 Example 58 Hydrophobic Phase: Isohexadecane 42.29 43.0 28.3Sodium dioctyl 10.62 7.0 7.1 sulfosuccinate² Hydrophilic Phase: Glycerin35.17 19.0 23.6 Water 11.72 19.0 7.8 Carnauba wax 29.0 Gelatin 6.0Active skin care ingredients: Triclosan 0.20 Titanium dioxide, cosmetic4.2 Titanium dioxide, micronized 4.2 Salicylic acid 1.8

[0353] Add skin care ingredients first to the phase which most closelymatches their solubility parameter. Then, stir all ingredients togetheruntil microemulsion forms. Coat onto substrate surface.

Examples 59-64

[0354] Prepare a representative conditioning component for the articlesof the present invention in the following manner. Example ExampleExample Example Example Example 59 60 61 62 63 64 Part A Sodium 15.06.51 6.20 5.9 lauroyl ether sulfate (SLES, add as 27% active)Cocamidopropyl 13.5 5.85 5.57 5.82 5.19 5.3 betaine¹ Sodium 1.35 0.600.57 6.01 5.36 0.54 lauroyl sarcosinate² Decylpoly- 5.80 5.18 glucose³Lauryl 1.31 0.56 0.54 0.54 alcohol Polyethyleneimine⁴ 7.87 3.38 3.222.64 2.36 3.2 Citric acid 0.32 0.11 0.11 0.09 (add as 50% aqueoussolution) Tetrasodium 0.28 EDTA Sulfuric acid 5.4 2.37 2.25 2.2Preservative, 0.62 0.45 0.43 2.86 2.55 0.3 fragrance Sodium 7.9 3.473.21 3.0 sulfate Glycerin 26.45 56.7 46.4 44.1 39.36 44.8 Sorbitol 5.0SEFA* 12.8 cottonate SEFA* 8.0 behenate Part B - Polymer gelling agentsGelatin 4.2 Polyacrylamide 7.5 and isoparaffin⁵ Polyurethane 34.1 latexin 50% isopropanol⁶ Polyacrylate 7.5 copolymer⁷ Polystyrene 1.1sulfonates copolymer⁸ Chitosan 5.4 lactate Part C - Physical gellingagents 12-Hydroxy- 10.0 10.66 stearic acid Stearyl 10.0 20.0 20.0 7.1115.0 alcohol

[0355] Blend the surfactants and fatty alcohol while heating to 65° C.with a low speed impeller mixer. Remove from heat, allow to cool to 65°C. while continuing to mix. Add the cationic polymer and stir untilhomogeneous. Slowly add remaining Part A ingredients while stirring.Homogenize to disperse the SEFA as an emulsion. Titrate withconcentrated sulfuric acid until a pH of about 6.5 is reached. Prepare adried mixture by spreading the Part A composition in trays and drying ina suitable (vacuum or convection) oven at a temperature not exceeding65° C. until essentially no water remains. Blend the dried Part Aingredients with the polymeric gelling agents from Part B, heat todissolve or disperse. Blend the resulting composition with the physicalgelling agents. Heat to melt and dissolve gelling agents into thecomposition. Apply to substrate surface(s) or cool to room temperatureand store.

Examples 65-70

[0356] Prepare a representative conditioning component for the articlesof the present invention as described in Examples 59-64 using thefollowing ingredients. Example Example Example Example Example Example65 66 67 68 69 70 Part A Sodium 8.87 11.4 10.8 10.8 lauroyl sarcosinate¹Polyethyleneimine² 7.39 7.50 7.50 9.5 9.0 9.0 Water 4.43 3.00 3.00 5.75.4 5.4 Sulfuric acid 6.36 QS QS 8.1 7.7 7.7 Fragrance, misc. Glycerin34.45 52.5 45.0 41.3 39.25 34.25 Propylene 2.50 glycol Urea 2.50 2.502.0 1.9 1.9 Panthenol 2.0 1.9 1.9 Nicotinamide 2.50 2.50 2.0 1.9 1.9Salicylic acid Polymethyl- 4.20 4.20 silsesquioxane 3 Mica, 3.85 3.85pearlescent Stearylmethicone 5.0 wax SEFA 5.0 cottonate Petrolatum 5.0Part B - Polymer gelling agents Gelatin 0.1 Polyacrylamide 16.0 12.012.0 and isoparaffin⁴ Part C - Physical gelling agents 12- 12.0 12.010.5 Hydroxystearic acid Carnauba wax 18.0 14.1 14.1 Stearyl 8.0 8.0 7.0alcohol

Examples 71-74

[0357] Prepare a representative skin conditioning component whichincludes the following components. Example Example Component 71 72Example 73 Example 74 SEFA* Cottonate 62.0 52.0 Petrolatum 4.5 StearylAlcohol 4.0 Stearic Acid 3.0 Lanolin 20.0 13.0 Ethylene vinyl 10.0 10.0acetate polymer¹ Polydecene² 2.0 2.0 Sodium lauroyl 25.0 3.00 3.0sarcosinate³ Lauryl betaine⁴ 1.50 2.0 Lauroamphoacetate⁵ 5.25 Sodiumlaureth-3 10.5 sulfate⁶ Cocamide MEA⁷ 2.80 Sulfuric acid QS Guar 0.500.50 hydroxypropyl- trimonium chloride Cholesterol⁸ 9.0 1.0 Nonylphenol5.0 polyglycine ether⁹ Micronized 4.0 titanium dioxide Octyl 4.0methoxycinnamate Nicotinamide 2.5 Glycerin 10.0 3.00 Water 48.5 55.95PEG 6 3.40 caprylic/capric glycerides Maleated 1.50 soybean oil Soybeanoil 8.0 (deodorized) Palm kernel fatty 2.60 acids Polyquaternium- 0.4010 Fragrance, 4.60 preservative, misc.

[0358] Melt the lipid components, add the water (if applicable) andhumectant(s), add the surfactant and continue to heat and stir untilhomogeneous. Cool to room temperature and add the skin care active(s)and deposition agent(s). Adjust pH to about 7.0 with sulfuric acid.Spray, roll, dip or otherwise apply to substrate and dry (if watercontaining) before packaging.

[0359] III. Personal Care Articles

Example 75

[0360] Prepare a representative skin cleansing article in the followingmanner.

[0361] Four grams of the cleansing component of Example 11 is applied toone side of a permeable, fusible web comprised of low-meltingheat-sealable polyamide fibers. The permeable web is Wonder Undermanufactured by Pellon, available from H. Levinson & Co., Chicago, Ill.The cleansing component is applied to an oval area approximately 13 cmby 18 cm. The cleansing component is air dried. A layer of 2 oz/sq ydpolyester batting cut to the same size as the web is placed over thefusible web. The polyester batting has a basis weight of 2 oz/yd² and iscomprised of a blend of fibers of about 23 microns and 40 micronsaverage diameter, at least some of which are crimped. The thickness ofthe batting is about 0.23 in. measured at 5 gsi. The batting is believedto be heat-bonded, utilizing no adhesive. A layer of a nonwoven isplaced under the fusible web to form the second side of the article. Thenonwoven is a spunlace blend of 70% rayon and 30% PET fibers, bondedwith a styrene-butadiene adhesive, which is hydroapertured to form holesabout 2 mm in diameter and having a basis weight of about 70 gsm. Theshape of the article is about 122 mm×160 mm oval. The layers are sealedtogether using point bonds in a grid pattern with a heat sealing dieutilizing a pressure-platen heat sealing device such as a Sentinel Model808 heat sealer available from Sencorp, Hyannis, Mass. The point bondsmeasure about 4 mm diameter each and there are about 51 individualsealing points evenly spaced. The article is trimmed and ready for use.

Example 76

[0362] Prepare a representative skin cleansing article in the followingmanner.

[0363] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 4.4 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second web which is an airlaid, lofty, lowdensity batting is continuously fed over the first substrate placing itin contact with the surfactant-containing layer. The batting comprises ablend of 30% 15 denier PET fibers, 35% 3 denier bicomponent fibers withPET core and PE sheath, and 35% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 100 grams persquare meter (gsm). The webs are continuously fed to an ultrasonicsealer which seals a dot pattern comprising a grid of 4 mm diametersealing points spaced evenly across the web. The web is cut intoindividual articles measuring about 120 mm×160 mm rectangles withrounded corners, which has a total of about 51 sealing points perarticle.

Example 77

[0364] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0365] Three grams of the skin conditioning composition of Example 34 isapplied, half to each side, of the finished article of Example 75. Thecomposition is applied by slot coating the composition as a hot liquid(60-70° C.) to the article surfaces evenly, half of the composition oneach side of the article.

Example 78

[0366] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0367] Three grams of the skin conditioning composition of Example 18 isapplied, half to each side, of the finished article of Example 75. Thecomposition is applied by slot coating the composition as a hot liquid(60-70° C.) to the article surfaces evenly, half of the composition oneach side of the article.

Example 79

[0368] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0369] Three grams of the skin conditioning composition of Example 65 isapplied, half to each side, of the finished article of Example 75. Thecomposition is applied by slot coating the composition as a hot liquid(60-70° C.) to the article surfaces evenly, half of the composition oneach side of the article.

Example 80

[0370] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0371] Three grams of the skin conditioning composition of Example 34 isapplied, half to each side, of the finished article of Example 76. Thecomposition is applied by slot coating the composition as a hot liquid(60-70° C.) to the article surfaces evenly, half of the composition oneach side of the article.

Example 81

[0372] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0373] Three grams of the skin conditioning composition of Example 18 isapplied, half to each side, of the finished article of Example 76. Thecomposition is applied by slot coating the composition as a hot liquid(60-70° C.) to the article surfaces evenly, half of the composition oneach side of the article.

Example 82

[0374] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0375] Three grams of the skin conditioning composition of Example 65 isapplied, half to each side, of the finished article of Example 76. Thecomposition is applied by slot coating the composition as a hot liquid(60-70° C.) to the article surfaces evenly, half of the composition oneach side of the article.

Example 83

[0376] Prepare a representative skin cleansing article in the followingmanner.

[0377] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 4.4 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second web which is an airlaid, lofty, lowdensity batting is continuously fed over the first substrate placing itin contact with the surfactant-containing layer. The batting comprises ablend of 30% 15 denier PET fibers, 35% 3 denier bicomponent fibers withPET core and PE sheath, and 35% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 100 grams persquare meter (gsm). The webs are continuously fed to an ultrasonicsealer which seals a dot pattern comprising a grid of 4 mm diametersealing points spaced evenly across the web. The web is cut intoindividual articles measuring about 120 mm×480 mm rectangles withrounded corners.

Example 84

[0378] Prepare a representative skin cleansing article in the followingmanner.

[0379] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 4.4 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second substrate web which is an airlaid,lofty, low density batting is continuously fed over the first substrateplacing it in contact with the surfactant-containing layer. The battingcomprises a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). A third substrate web which is the same asthe second substrate web is continuously fed over the second substrateweb placing it in contact with the second substrate. The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. The web is cut into individual articles measuring about 120mm×90 mm rectangles with rounded corners.

Example 85

[0380] Prepare a representative skin cleansing article in the followingmanner.

[0381] Four grams of the cleansing component of Example 12 is applied toone side of a permeable, fusible web comprised of low-meltingheat-sealable polyamide fibers. The permeable web is Wonder Undermanufactured by Pellon, available from H. Levinson & Co., Chicago, Ill.The cleansing component is applied to an oval area approximately 13 cmby 18 cm. The cleansing component is air dried. A layer of 2 oz/sq ydpolyester batting cut to the same size as the web is placed over thefusible web. The polyester batting has a basis weight of 2 oz/yd² and iscomprised of a blend of fibers of about 23 microns and 40 micronsaverage diameter, at least some of which are crimped. The thickness ofthe batting is about 0.23 in. measured at 5 gsi. The batting has an airpermeability of about 1270 cfm/ft² and a foam permeability criticalpressure of about 2.7 cm H₂O. The batting is believed to be heat-bonded,utilizing no adhesive. A layer of a nonwoven is placed under the fusibleweb to form the second side of the article. The nonwoven is a spunlaceblend of 70% rayon and 30% PET fibers, bonded with a styrene-butadieneadhesive, which is hydroapertured to form holes about 2 mm in diameterand having a basis weight of about 70 gsm. The shape of the article isabout 122 mm×160 mm oval. The layers are sealed together using pointbonds in a grid pattern with a heat sealing die utilizing apressure-platen heat sealing device such as a Sentinel Model 808 heatsealer available from Sencorp, Hyannis, Mass. The point bonds measureabout 4 mm diameter each and there are about 51 individual sealingpoints evenly spaced. The article is trimmed and ready for use.

Examples 86-88

[0382] Prepare representative skin cleansing articles with the cleansingcomponents of Examples 1, 2 and 5 in the following manner.

[0383] Eight grams of cleansing component is applied to one side of apermeable, fusible web comprised of low-melting heat-sealable fibers infour quadrants forming a rectangle about 10 inches by 12 inches, leavingspace at the edge and between quadrants to seal layers without thepresence of surfactant. The permeable web is a fibrous, low densitypolyethylene (LDPE or LLDPE) material commonly available from sewingsupply distributors. A layer of 4 oz/sq yd polyester batting cut to thesame size as the web is placed over the fusible web. The polyesterbatting has a basis weight of 4 oz/yd² and is comprised of polyesterfibers of about 30 microns average diameter and is adhesive bonded,available for example as Mountain Mist Extra Heavy Batting #205 fromStearns Textiles, Cincinnati, Ohio. A layer of fibrous nonwoven which isa hydroentangled blend of 55% cellulose and 45% polyester having a basisweight of about 65 gsm (available as Technicloth II from The TexwipeCompany, Saddle River, N.J.) is placed under the fusible web. The layersare sealed together in a rectangular windowpane shape with a heatsealing die utilizing a pressure-platen heat sealing device such as aSentinel Model 808 heat sealer available from Sencorp, Hyannis, Mass.with sufficient temperature and pressure to cause the batting to meltand flow into the first layer and hence form an adequate seal, usuallyabout 300 degrees Fahrenheit and 30 psi machine pressure sealing for6-10 seconds is sufficient. The seal is continuous around the edges andhas a single windowpane cross-member in each X- and Y-directionmeasuring about 2 mm width. After cooling the article is trimmed and thecorners rounded and it is stored until ready for use.

Examples 89-90

[0384] Prepare representative skin cleansing and conditioning articleswith the cleansing component powders of Examples 3 and 4 in thefollowing manner.

[0385] Four grams of dry cleansing component powder is applied to oneside of a permeable, fusible web comprised of low-melting heat-sealablefibers. The permeable web is Wonder Under manufactured by Pellon,available from H. Levinson & Co., Chicago, Ill. The powder is sprinkledevenly over an oval area approximately 17 cm by 19 cm. A layer of 2oz/sq yd polyester batting cut to the same size as the web is placedover the fusible web. The polyester batting has a basis weight of 2oz/yd² and is comprised of a blend of fibers of about 23 microns and 40microns average diameter, at least some of which are crimped. Thethickness of the batting is about 0.23 in. measured at 5 gsi. Thebatting has an air permeability of about 1270 cfm/ft² and a foampermeability critical pressure of about 2.7 cm H₂O. The batting isbelieved to be heat-bonded, utilizing no adhesive. A second nonwovenlayer is prepared which is hydroapertured, comprising polyester fibersof about 10 microns diameter and containing within it an interlacedpolypropylene scrim having a fiber diameter about 150 microns, laced atabout 0.8 cm intervals. The second layer is cut larger than the requiredarticle dimensions and placed in a convection oven at a temperature ofabout 150 degrees Celsius for about 10 minutes, until the X- andY-dimensions of the layer have shrunk to about 70 percent of theiroriginal size and the layer has a macroscopic thickness of about 0.12in. measured at 5 gsi. The layer has a macroscopic average basis weightof about 64 gsm before shrinking, and apertures measuring about 0.5 mmaverage diameter. The second layer is placed under the fusible web andthe layers are sealed together using point bonds and also a 2 mm wideseal around the perimeter with a heat sealing die utilizing apressure-platen heat sealing device such as a Sentinel Model 808 heatsealer available from Sencorp, Hyannis, Mass. The point bonds measureabout 3 mm diameter each and there are about 51 individual sealingpoints evenly spaced. The article is trimmed, and 2.5 grams of the skinconditioning composition of Example 25 is applied to the lofty battingside of the article by feeding the composition through a slotted rollingdevice with a machined 1.5 mm gap and a feed reservoir held at about 60°C. The composition quickly cools on the article surface and is stored ina sealed, metallized film package until ready for use.

Examples 91-96

[0386] Prepare representative skin cleansing and conditioning articleswith the liquid cleansing components of Examples 6, 8, 9, 15, 16 and 17in the following manner.

[0387] Liquid cleansing component is applied to one side of a firstsubstrate by coating with a brush until 2 grams of solid cleansingcomponent has been applied, in a windowpane design avoiding the edgesand the sealing loci. The substrate is a spunlace blend of 70% rayon and30% PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. The substrates are air dried in a convectionoven at 45° C. for about 6 hours or until dry to the touch. A secondsubstrate which is an airlaid, lofty, low density batting is placed overthe first substrate placing it in contact with the surfactant-containinglayer. The batting comprises a blend of 30% 15 denier PET fibers, 35% 3denier bicomponent fibers with PET core and PE sheath, and 35% 10 denierbicomponent fibers of the same core-sheath composition, and has a basisweight of about 100 grams per square meter (gsm). The layers are sealedtogether in a rectangular windowpane shape with a heat sealing dieutilizing a pressure-platen heat sealing device such as a Sentinel Model808 heat sealer available from Sencorp, Hyannis, Mass. with sufficienttemperature and pressure to cause the batting to melt and flow into thefirst layer and hence form an adequate seal, usually about 300 degreesFahrenheit and 30 psi machine pressure sealing for 6-10 seconds issufficient. The seal is continuous around the edges and has a singlewindowpane cross-member in each X- and Y-direction measuring about 2 mmwidth. After cooling the article is trimmed and 3 grams of the skinconditioning composition of Example 26 is applied to the lofty battingside of the article by feeding the composition through a slotted rollingdevice with a machined 1.5 mm gap and a feed reservoir held at about 60°C. The composition quickly cools on the article surface and is stored ina sealed, metallized film package until ready for use.

Examples 97-102

[0388] Prepare representative skin cleansing and conditioning articleswith the liquid cleansing components of Example 7 and the skinconditioning compositions of Examples 19 through 24 in the followingmanner.

[0389] Four strips of the liquid cleansing component are extrudedcontinuously on a moving first web which is an airlaid, lofty, lowdensity batting. The batting comprises a blend of 30% 15 denier PETfibers, 35% 3 denier bicomponent fibers with PET core and PE sheath, and35% 10 denier bicomponent fibers of the same core-sheath composition,and has a basis weight of about 100 grams per square meter (gsm), and isairlaid and heat bonded with no adhesive. The liquid cleansing componentis heated to melting point and held in a reservoir at about 65° C. andfed by pump to an extrusion head which continuously meters 4 cylindricalstrands onto the web at even spacing across the web, to achieve a finaladd-on rate of about 5 grams of composition per finished article. Asecond web which is a microapertured and macroapertured formed filmwhich is the formed film of U.S. Pat. No. 4,629,643 is continuously fedonto the first web, macroapertured male side towards the batting andcleansing component. The skin conditioning composition is slot coatedevenly onto the exposed batting surface at a rate of 3 grams ofcomposition per finished article while hot, cooling on the articlesurface to solidify. The webs are continuously sealed and cut into 120mm by 160 mm rectangles with rounded corners using a heated metal rolland a pressure roll applied against the formed film side. The articlesare packaged until ready for use.

Examples 103-105

[0390] Prepare representative skin cleansing and conditioning articleswith the liquid cleansing component of Example 6 and the skinconditioning compositions of Examples 56, 57 and 58 in the followingmanner.

[0391] Liquid cleansing component is applied to one side of a firstsubstrate by coating with a brush until 2 grams of solid surfactant hasbeen applied, in a windowpane design avoiding the edges and the sealingloci. The substrate is an airlaid, lofty, low density batting comprisinga blend of 30% 15 denier PET fibers, 35% 3 denier bicomponent fiberswith PET core and PE sheath, and 35% 10 denier bicomponent fibers of thesame core-sheath composition, and has a basis weight of about 100 gramsper square meter (gsm). The cleansing component is dried. A secondsubstrate which is a high wet strength, adhesive bonded cellulose papertowel with good loft and a basis weight of about 53 gsm is placed overthe cleansing component exposed side of the batting. A useful towel isavailable from The Procter & Gamble Company and marketed as Bounty Rinse& Reuse®, which retains its Z-direction height when wet, and which has athickness of about 0.047 inches at 5 gsi and a Loft/Soft ratio of about1.28. The layers are sealed together in a rectangular windowpane shapewith a heat sealing die utilizing a pressure-platen heat sealing devicesuch as a Sentinel Model 808 heat sealer available from Sencorp,Hyannis, Mass. with sufficient temperature and pressure to form anadequate seal. The seal is continuous around the edges and has a singlewindowpane cross-member in each X- and Y-direction measuring about 2 mmwidth. The article is trimmed, and 1.5 grams of skin conditioningcomposition is applied to the lofty batting side of the article byfeeding the composition through a slotted rolling device with a machined1.5 mm gap and a feed reservoir held at about 60° C. The compositionquickly cools on the article surface and is stored in a sealed,metallized film package until ready for use.

Example 106

[0392] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0393] The cleansing component of Example 12 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 4.4 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second substrate web which is an airlaid,lofty, low density batting is continuously fed over the first substrateplacing it in contact with the surfactant layer. The batting comprises ablend of 30% 15 denier PET fibers, 35% 3 denier bicomponent fibers withPET core and PE sheath, and 35% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 100 grams persquare meter (gsm). A third substrate web which is the same as thesecond substrate web is continuously fed over the second substrate webplacing it in contact with the second substrate. The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. The skin conditioning liquid of Example 53 is sprayed onto theweb at a rate of about 25 gsm per side, or about 0.5 grams ofcomposition per finished article. The web is cut into individualarticles measuring about 120 mm×90 mm rectangles with rounded cornersand packaged until ready for use.

Example 107-108

[0394] Prepare representative skin cleansing and conditioning articlesin the following manner, utilizing the skin conditioning compositions ofExamples 54 and 55.

[0395] The low water activity cleansing component of Example 2 isthree-roll milled with aluminosilicate (available as Advera 401 N fromThe PQ Corporation, Valley Forge, Pa., which generates heat due to anexothermic reaction upon exposure to water) in a ratio of 1:1. Ten gramsthe cleansing component is applied to one side of a layer of batting.The batting is an airlaid, lofty, low density batting comprising a blendof 30% 15 denier PET fibers, 35% 3 denier bicomponent fibers with PETcore and PE sheath, and 35% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 100 grams persquare meter (gsm). The surfactant is applied fibers in four quadrantstogether forming a rectangle about 10 inches by 12 inches, leaving spaceat the edge and between quadrants to seal layers without the presence ofsurfactant. A second nonwoven layer is prepared which is hydroapertured,comprising polyester fibers of about 10 microns diameter and containingwithin it an interlaced scrim having a fiber diameters about 100 micronsrunning across the width of the nonwoven and about 250 micronsorthogonal to the width, laced (bonded) at about 1 cm intervals. Such ascrim is available from Conwed plastics, Minneapolis, Minn. The secondnonwoven has a basis weight of about 70 gsm, and is slightly creped dueto web tension during manufacture of the nonwoven, and subsequentrelaxation of the tension. The layers are sealed together using pointbonds and also a 2 mm wide seal around the perimeter with a heat sealingdie utilizing a pressure-platen heat sealing device such as a SentinelModel 808 heat sealer available from Sencorp, Hyannis, Mass. The pointbonds measure about 3 mm diameter each and there are about 51 individualsealing points evenly spaced. The article is trimmed, and 4 grams ofskin conditioning composition is applied to the lofty batting side ofthe article by feeding the composition through a slotted rolling devicewith a machined 1.5 mm gap and a feed reservoir held at about 60° C. Thecomposition quickly cools on the article surface and is stored in asealed, metallized film package until ready for use.

Examples 109-116

[0396] Prepare representative skin cleansing and conditioning articlesin the following manner, utilizing the skin conditioning compositions ofExamples 59, 60, 61, 62, 63, 68, 69 and 70.

[0397] Four grams of the cleansing component of Example 11 is spreadevenly by hand across a lofty batting. The batting is an airlaid, lofty,low density batting comprising a blend of 30% 15 denier PET fibers, 35%3 denier bicomponent fibers with PET core and PE sheath, and 35% 10denier bicomponent fibers of the same core-sheath composition, and has abasis weight of about 100 grams per square meter (gsm). A layer offibrous nonwoven which is a hydroentangled blend of 55% cellulose and45% polyester having a basis weight of about 65 gsm (available asTechnicloth II from The Texwipe Company, Saddle River, N.J.) is placedover the cleansing component coated side of the batting. The layers aresealed together using interlocking sealing plates using an unheatedplate having inverted thimble-shaped reservoirs spaced evenly in ahexagonal grid pattern. The thimble shaped reservoirs are about 1.2 cmdiameter at the base and are spaced about 2 cm apart, center-to-center.The land area between the dimples on the unheated plate is concaveinwards by several mm, forming an interconnected trough. The heatedplate has an external ridge which fit precisely into the trough on theland area of the unheated plate. The heated plate contacts thecellulose/polyester substrate and a heat seal is effected usingpressure-platen heat sealing device such as a Sentinel Model 808 heatsealer available from Sencorp, Hyannis, Mass. The resulting unfinishedarticle has pronounced thimble shapes rising up on the batting side, andshorter dimples or ‘buttons’ rising up on the cellulose/polyestersubstrate side of the article, making both sides easy to grip. Thearticle is cut into a rectangle about 120 mm by 160 mm. Three grams ofskin conditioning composition per article is pipetted into the trougharea while the composition is hot, and allowed to cool and solidify. Thearticle is packaged until ready for use.

Example 117

[0398] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0399] Eight grams of the liquid cleansing component of Example 10cleansing component is applied by brush to one side of a permeable,fusible web comprised of low-melting heat-sealable fibers in fourquadrants forming a rectangle about 10 inches by 12 inches, leavingspace at the edge and between quadrants to seal layers without thepresence of cleansing component. The permeable web is a fibrous, lowdensity polyethylene (LDPE or LLDPE) material commonly available fromsewing supply distributors. The composition is dried. A layer of 4 oz/sqyd polyester batting cut to the same size as the web is placed over thefusible web. The polyester batting has a basis weight of 4 oz/yd² and iscomprised of polyester fibers of about 30 microns average diameter andis adhesive bonded, available for example as Mountain Mist Extra HeavyBatting #205 from Stearns Textiles, Cincinnati, Ohio. A layer of fibrousnonwoven which is a hydroentangled blend of 55% cellulose and 45%polyester having a basis weight of about 65 gsm (available asTechnicloth II from The Texwipe Company, Saddle River, N.J.) is placedunder the fusible web. The layers are sealed together in a rectangularwindowpane shape with a heat sealing die utilizing a pressure-platenheat sealing device such as a Sentinel Model 808 heat sealer availablefrom Sencorp, Hyannis, Mass. with sufficient temperature and pressure tocause the batting to melt and flow into the first layer and hence forman adequate seal, usually about 300 degrees Fahrenheit and 30 psimachine pressure sealing for 6-10 seconds is sufficient. The seal iscontinuous around the edges and has a single windowpane cross-member ineach X- and Y-direction measuring about 2 mm width. Five grams of theconditioning composition of Example 64 is brush applied to the article,half to each side, and the article is again dried. The article istrimmed, the corners rounded and it is stored until ready for use.

Example 118-119

[0400] Prepare representative skin cleansing and conditioning articlesutilizing the skin conditioning compositions of Examples 66 and 67 inthe following manner.

[0401] The liquid cleansing component of Example 15 is applied to afirst substrate by dipping a 120 mm by 160 mm section of the substratein a bath of the composition until it has increased its weight by about8 grams. The substrate is a batting comprising a blend of 30% 15 denierPET fibers, 35% 3 denier bicomponent fibers with PET core and PE sheath,and 35% 10 denier bicomponent fibers of the same core-sheathcomposition, and has a basis weight of about 100 grams per square meter(gsm). The substrate is dried. A piece of a second substrate which is aspunlace blend of 70% rayon and 30% PET fibers, bonded with astyrene-butadiene adhesive and hydroapertured to form holes about 2 mmin diameter, having a basis weight of about 70 gsm is placed over thefirst substrate. The substrates are sealed together using an ultrasonicsealer which seals a dot pattern comprising a grid of 4 mm diametersealing points spaced evenly across the article. Four grams of skinconditioning composition is applied evenly over both sides of thearticle by feeding the composition through a slotted rolling device witha machined 1.5 mm gap and a feed reservoir held at about 60° C. Thecomposition quickly cools on the article surface and is stored in asealed, metallized film package until ready for use.

Example 120-124

[0402] Prepare representative skin cleansing and conditioning articlesutilizing the skin conditioning compositions of Examples 27 through 31in the following manner.

[0403] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 4.4 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second substrate web which is an airlaid,lofty, low density batting is continuously fed over the first substrateplacing it in contact with the surfactant-containing ayer. The battingcomprises a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). A third substrate web which is the same asthe second substrate web is continuously fed over the second substrateweb placing it in contact with the second substrate. The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. Skin conditioning composition is slot coated from a hotreservoir pumped through a slot dye onto both sides of the substrate webat a rate equal to 3 grams of skin conditioning composition per finishedarticle (about 140 gsm add-on per side), and passed across a cooling fanso the composition cools quickly on the article outer surfaces. The webis cut into individual articles measuring about 120 mm×90 mm rectangleswith rounded corners.

Examples 125-145

[0404] Prepare representative skin cleansing and conditioning articlesutilizing the skin conditioning compositions of Examples 32 through 52in the following manner.

[0405] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 4.4 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second substrate web which is an airlaid,lofty, low density batting is continuously fed over the first substrateplacing it in contact with the surfactant-containing layer. The battingcomprises a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). A third substrate web which is the same asthe second substrate web is continuously fed over the second substrateweb placing it in contact with the second substrate. The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. Skin conditioning composition is slot coated from a hotreservoir pumped through a slot dye onto both sides of the substrate webat a rate equal to 3 grams of skin conditioning composition per finishedarticle (about 140 gsm add-on per side), and passed across a cooling fanso the composition cools quickly on the article outer surfaces. The slotcoating reservoir is continuously mixed to maintain stability of theemulsion. The web is cut into individual articles measuring about 120mm×90 mm rectangles with rounded corners.

Examples 146-147

[0406] Prepare representative skin cleansing and conditioning articlesutilizing the skin cleansing and conditioning compositions of Examples71 and 74 in the following manner.

[0407] A first substrate and a second substrate are cut to about 12 inchby 9 inch rectangles. The first substrate is a spunlace blend of 70%rayon and 30% PET fibers, bonded with a styrene-butadiene adhesive,which is hydroapertured to form holes about 2 mm in diameter and havinga basis weight of about 70 gsm. The second substrate is a battingcomprising a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). The substrates are sealed together in awindowpane design with a heat sealing die utilizing a pressure-platenheat sealing device such as a Sentinel Model 808 heat sealer availablefrom Sencorp, Hyannis, Mass. with sufficient temperature and pressure tocause the batting to melt and flow into the first layer and hence forman adequate seal, usually about 300 degrees Fahrenheit and 30 psimachine pressure sealing for 6-10 seconds is sufficient. The seal iscontinuous around the edges and has a single windowpane cross-member ineach X- and Y-direction measuring about 2 mm width. After cooling thearticle is trimmed to about 11 inches by 8.5 inches, and 10 grams ofskin cleansing and conditioning composition is brushed onto the outersurfaces of both sides, about half the composition per side. Thecomposition is dried and the article is stored until ready for use.

Examples 148-149

[0408] Prepare representative skin cleansing and conditioning articlesutilizing the skin cleansing and conditioning compositions of Examples72 and 73 in the following manner.

[0409] A first substrate and a second substrate are cut to about 12 inchby 9 inch rectangles. The first substrate is a spunlace blend of 70%rayon and 30% PET fibers, bonded with a styrene-butadiene adhesive,which is hydroapertured to form holes about 2 mm in diameter and havinga basis weight of about 70 gsm. The second substrate is a battingcomprising a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). The substrates are sealed together in awindowpane design with a heat sealing die utilizing a pressure-platenheat sealing device such as a Sentinel Model 808 heat sealer availablefrom Sencorp, Hyannis, Mass. with sufficient temperature and pressure tocause the batting to melt and flow into the first layer and hence forman adequate seal, usually about 300 degrees Fahrenheit and 30 psimachine pressure sealing for 6-10 seconds is sufficient. The seal iscontinuous around the edges and has a single windowpane cross-member ineach X- and Y-direction measuring about 2 mm width. After cooling thearticle is trimmed to about 11 inches by 8.5 inches, and 8 grams of skincleansing and conditioning composition is slot coated onto the articles,4 grams per side evenly distributed on the article surfaces using an X-Ytable, which is a programmable controlled metering system comprising aheated reservoir maintained at about 70° C., a pump, an on-off valve, aslot head and a motorized X-Y coordinate control system for the coatinghead. The composition cools quickly on the surface of the articles. Thearticles are packaged until ready for use.

Examples 150-152

[0410] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0411] Prepare liquid cleansing components which include the followingcomponents: Component Example 150 Example 151 Example 152 Sodium laureth3 sulfate 3.60 Sodium C13/C14 methyl 5.00 5.60 4.50 branched sulfateSodium paraffin Sulfonate 6.40 Sodium alpha olefin sulfonate 5.20 Sodiumlauryl sulfate 5.50 Sodium lauroamphoacetate 4.50 5.30 3.65 Cocamide MEA3.55 3.20 2.80 Succinic acid 2.80 5.70 6.00 Sodium succinate 0.10 0.140.30 Citric acid 3.00 4.30 5.00 Sodium citrate 1.60 1.10 1.40 Malonicacid 4.00 2.20 Glycerine 10.00 15.00 8.50 Palm kernel 12-18 fatty acid2.00 3.00 Perfume 1.00 1.20 1.00 MgSO4-7H2O 0.89 0.90 0.80 Water 54.2147.61 52.25 Salicylic acid 1.85 Triclosan 0.25 Trichlorocarbanilide 1.10Zinc pyrithione 2.00

[0412] The cleansing components are applied to one side of a firstsubstrate by brushing onto one side of the substrate until 10 grams ofcomposition have been added to a 11 inch by 8.5 inch section. Thesubstrate is a lofty, low density batting comprising a blend of 30% 15denier PET fibers, 35% 3 denier bicomponent fibers with PET core and PEsheath, and 35% 10 denier bicomponent fibers of the same core-sheathcomposition, and has a basis weight of about 100 gsm. The firstsubstrate is dried. A second substrate is laminated to the untreatedside of the first substrate using an ultrasonic sealer which seals a dotpattern comprising a grid of 4 mm diameter sealing points spaced evenlyacross the web at 2 cm intervals. The second substrate is a spunlaceblend of 70% rayon and 30% PET fibers, bonded with a styrene-butadieneadhesive, which is hydroapertured to form holes about 2 mm in diameterand having a basis weight of about 70 gsm. The skin conditioningcomposition of Example 19 is slot coated evenly onto entire surface ofthe second substrate at a rate of about 3 grams of composition perarticle, allowed to cool, and packaged until ready for use. The articleconfers sustained antiviral, antifungal and antibacterial activityagainst both gram negative and gram positive microorganisms, latherswell, and is relatively mild to the skin.

Example 153

[0413] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0414] Four grams of the cleansing component of Example 11 is spreadevenly by hand across a lofty batting. The batting is a 4 oz/sq ydpolyester batting cut to a size of 130 mm by 175 mm, comprisingpolyester fibers of about 30 microns average diameter and is adhesivebonded, available for example as Mountain Mist Extra Heavy Batting #205from Stearns Textiles, Cincinnati, Ohio. A layer of fibrous nonwovenwhich is a hydroentangled blend of 55% cellulose and 45% polyesterhaving a basis weight of about 65 gsm (available as Technicloth II fromThe Texwipe Company, Saddle River, N.J.) is placed over the surfactantcoated side of the batting. The layers are sealed together usinginterlocking sealing plates using an unheated plate having invertedthimble-shaped reservoirs spaced evenly in a hexagonal grid pattern. Thethimble shaped reservoirs are about 1.2 cm diameter at the base and arespaced about 1.5 cm apart, center-to-center. The land area between thedimples on the unheated plate is convex upwards by several mm, formingan interconnected ridge. The heated plate has an external trough whichfits precisely onto the ridge of the unheated plate. The heated platecontacts the cellulose/polyester substrate and a heat seal is effectedusing a pressure-platen heat sealing device such as a Sentinel Model 808heat sealer available from Sencorp, Hyannis, Mass. The resultingunfinished article has topographical features on both sides, assistinglather generation and also making it easy to grip and slide across theskin surface during use. The article is cut into a rectangle about 120mm by 160 mm.

[0415] A skin conditioning inverse emulsion paste is prepared for usewith the article, as follows: Component Percent PEG30-dipolyhydroxystearate 3.0 SEFA cottonate 20.0 Petrolatum 4.0Tribehenin 5.0 C10-C30 Cholesterol/Lanosterol Esters 13.0 SEFA behenate5.0 Glycerin 50.0

[0416] The lipid soluble ingredients are heated to 70° C. whilestirring. Glycerin is slowly added with vigorous stirring. Thecomposition is homogenized. Three grams of the skin conditioning inverseemulsion paste is pipetted hot into the depressed zones on thecellulose/polyester side of the article. The composition quickly coolsto a semi-solid paste. The article is packaged until ready for use.

Examples 154-158

[0417] Prepare representative skin conditioning articles in thefollowing manner using the skin conditioning compositions of Examples19, 29, 34, 55, and 60.

[0418] The conditioning composition is applied to one side of a firstsubstrate by extruding it through a coating head continuously in fourstrips, each 5 mm wide, separated by a distance of 20 mm, 40 mm, and 20mm respectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The composition is extruded at arate to yield 3 grams of composition per finished article. The substrateis a spunlace blend of 70% rayon and 30% PET fibers, bonded with astyrene-butadiene adhesive, which is hydroapertured to form holes about2 mm in diameter and having a basis weight of about 70 gsm. A second webwhich is an airlaid, lofty, low density batting is continuously fed overthe first substrate placing it in contact with the first substrate onthe side containing no skin conditioning composition. The battingcomprises a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). The webs are continuously fed to anultrasonic sealer which seals a dot pattern comprising a grid of 4 mmdiameter sealing points spaced evenly across the web. The web is cutinto individual articles measuring about 120 mm×160 mm rectangles withrounded corners, which has a total of about 51 sealing points perarticle.

Examples 159-163

[0419] Prepare representative skin conditioning articles in thefollowing manner using the skin conditioning compositions of Examples19, 28, 34, 55, and 69.

[0420] The conditioning composition is applied to one side of a firstsubstrate by extruding it through a coating head continuously in fourstrips, each 5 mm wide, separated by a distance of 20 mm, 40 mm, and 20mm respectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The composition is extruded at arate to yield 1.1 grams of composition per finished article. Thesubstrate is a spunlace blend of 70% rayon and 30% PET fibers, bondedwith a styrene-butadiene adhesive, which is hydroapertured to form holesabout 2 mm in diameter and having a basis weight of about 70 gsm. Asecond web which is an airlaid, lofty, low density batting iscontinuously fed over the first substrate placing it in contact with thefirst substrate on the side containing no skin conditioning composition.The batting comprises a blend of 10% 15 denier PET fibers, 50% 3 denierbicomponent fibers with PET core and PE sheath, and 40% 10 denierbicomponent fibers of the same core-sheath composition, and has a basisweight of about 80 grams per square meter (gsm). The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. The web is cut into individual articles measuring about 120mm×90 mm rectangles with rounded corners, which has a total of about 51sealing points per article. The article is convenient for application tosmaller areas of skin, for example the face, elbows, neck and/or feet.

Example 164

[0421] Prepare a representative skin cleansing article in the followingmanner.

[0422] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 0.40 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second substrate web which is an airlaid, lowdensity batting is continuously fed over the first substrate placing itin contact with the surfactant layer. The batting comprises a blend of10% 15 denier PET fibers, 50% 3 denier bicomponent fibers with PET coreand PE sheath, and 40% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 80 grams persquare meter (gsm). A third substrate web which is the same as thesecond substrate web is continuously fed over the second substrate webplacing it in contact with the second substrate. The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. The web is cut into individual articles measuring about 120mm×90 mm rectangles with rounded corners.

Example 165-169

[0423] Prepare representative skin cleansing and conditioning articlesutilizing the skin conditioning compositions of Examples 19, 28, 34, 55,and 69.

[0424] The cleansing component of Example 11 is applied to one side of afirst substrate by extruding it through a coating head continuously infour lines separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The cleansing component isextruded at a rate to yield 0.52 grams of cleansing component perfinished article. The substrate is a spunlace blend of 70% rayon and 30%PET fibers, bonded with a styrene-butadiene adhesive, which ishydroapertured to form holes about 2 mm in diameter and having a basisweight of about 70 gsm. A second substrate web which is an airlaid,lofty, low density batting is continuously fed over the first substrateplacing it in contact with the surfactant layer. The batting comprises ablend of 10% 15 denier PET fibers, 50% 3 denier bicomponent fibers withPET core and PE sheath, and 40% 10 denier bicomponent fibers of the samecore-sheath composition, and has a basis weight of about 80 grams persquare meter (gsm). A third substrate web which is the same as thesecond substrate web is continuously fed over the second substrate webplacing it in contact with the second substrate. The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. Skin conditioning composition is slot coated from a hotreservoir pumped through a slot dye onto both sides of the substrate webat a rate equal to 1.25 grams of skin conditioning composition perfinished article (about 55 gsm add-on per side), and passed across acooling fan so the composition cools quickly on the article outersurfaces. The web is cut into individual articles measuring about 120mm×90 mm rectangles with rounded corners.

Example 170

[0425] Prepare representative skin cleansing and conditioning kits inthe following manner.

[0426] A skin cleansing article is prepared. The cleansing component ofExample 11 is applied to one side of a first substrate by extruding itthrough a coating head continuously in four lines separated by adistance of 20 mm, 40 mm, and 20 mm respectively, measuring widthwiseacross the web, making a pair of parallel lines on each side of the web.The cleansing component is extruded at a rate to yield 4.4 grams ofcleansing component per finished article. The substrate is a spunlaceblend of 70% rayon and 30% PET fibers, bonded with a styrene-butadieneadhesive, which is hydroapertured to form holes about 2 mm in diameterand having a basis weight of about 70 gsm. A second web which is anairlaid, lofty, low density batting is continuously fed over the firstsubstrate placing it in contact with the surfactant-containing layer.The batting comprises a blend of 30% 15 denier PET fibers, 35% 3 denierbicomponent fibers with PET core and PE sheath, and 35% 10 denierbicomponent fibers of the same core-sheath composition, and has a basisweight of about 100 grams per square meter (gsm). The webs arecontinuously fed to an ultrasonic sealer which seals a dot patterncomprising a grid of 4 mm diameter sealing points spaced evenly acrossthe web. The web is cut into individual articles measuring about 120mm×480 mm rectangles with rounded corners.

[0427] A skin conditioning article is prepared. The conditioningcomposition of Example 34 is applied to one side of a first substrate byextruding it through a coating head continuously in four strips, each 5mm wide, separated by a distance of 20 mm, 40 mm, and 20 mmrespectively, measuring widthwise across the web, making a pair ofparallel lines on each side of the web. The composition is extruded at arate to yield 3 grams of composition per finished article. The substrateis a spunlace blend of 70% rayon and 30% PET fibers, bonded with astyrene-butadiene adhesive, which is hydroapertured to form holes about2 mm in diameter and having a basis weight of about 70 gsm. A second webwhich is an airlaid, lofty, low density batting is continuously fed overthe first substrate placing it in contact with the first substrate onthe side containing no skin conditioning composition. The battingcomprises a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). The webs are continuously fed to anultrasonic sealer which seals a dot pattern comprising a grid of 4 mmdiameter sealing points spaced evenly across the web. The web is cutinto individual articles measuring about 120 mm×160 mm rectangles withrounded corners, which has a total of about 51 sealing points perarticle.

[0428] The skin cleansing article and the skin conditioning article arepackaged together in a single package.

Example 171

[0429] Prepare representative skin cleansing and conditioning kits inthe following manner.

[0430] A skin cleansing article is prepared. The cleansing component ofExample 11 is applied to one side of a first substrate by extruding itthrough a coating head continuously in four lines separated by adistance of 20 mm, 40 mm, and 20 mm respectively, measuring widthwiseacross the web, making a pair of parallel lines on each side of the web.The cleansing component is extruded at a rate to yield 4.4 grams ofcleansing component per finished article. The substrate is a spunlaceblend of 70% rayon and 30% PET fibers, bonded with a styrene-butadieneadhesive, which is hydroapertured to form holes about 2 mm in diameterand having a basis weight of about 70 gsm. A second web which is anairlaid, lofty, low density batting is continuously fed over the firstsubstrate placing it in contact with the surfactant layer. The battingcomprises a blend of 30% 15 denier PET fibers, 35% 3 denier bicomponentfibers with PET core and PE sheath, and 35% 10 denier bicomponent fibersof the same core-sheath composition, and has a basis weight of about 100grams per square meter (gsm). The webs are continuously fed to anultrasonic sealer which seals a dot pattern comprising a grid of 4 mmdiameter sealing points spaced evenly across the web. The web is cutinto individual articles measuring about 120 mm×480 mm rectangles withrounded corners.

[0431] A skin conditioning article is prepared. A substrate is preparedwhich is a hydroentangled blend of fibers, having softer, finer denierfibers on one side and coarser fibers on the second side. The substrateis prepared by airlaying two webs comprising 10 denier polyester (PET)fibers, one web on top of the other, each having a basis weight of about20 gsm. A web of polypropylene scrim having a diameter about 100microns, laced at about 0.8 cm intervals is fed over the fibrous webscontinuously as a third web. Fourth and fifth webs comprising 3 denierpolyester fibers are airlaid at about 20 gsm each on top of the web. Thewebs are hydroentangled and to fix them into a single web unit, anddried on drying cans until moisture free and about 20% shrinkage due torelaxation of the scrim has occurred. A low Tg (about 5° C.) waterborneacrylic adhesive copolymer is added to the coarse fiber side of the webby kiss roll application at a rate of about 7 gsm wet add-on rate, anddried. The skin conditioning composition of Example 21 is continuouslyadded to the web by slot coating the composition evenly across bothsides of the web at a rate of about 25 gsm on each side. The substrateweb is cut into individual articles measuring about 120 mm×100 mmrectangles with rounded corners using a hot cutting roll causing thescrim fibers to shrink back slightly from the edge of the article asthey are cut.

[0432] The skin cleansing article and the skin conditioning article arepackaged together in a single package.

Example 172

[0433] Prepare representative skin cleansing and conditioning article inthe following manner.

[0434] A first substrate is prepared. The first substrate is an airlaid,lofty, low density batting comprising a blend of 30% 15 denier PETfibers, 35% 3 denier bicomponent fibers with PET core and PE sheath, and35% 10 denier bicomponent fibers of the same core-sheath composition,and has a basis weight of about 100 grams per square meter (gsm). Thebatting is embossed with a shaped, heated embossing roll leaving animprinted land area surrounding raised, button-like repeating unitswhich are shaped like light bulbs and which forms a materialrepresentative of a loop portion of a hook-and-loop type fasteningsystem. Such a material is available from PGI Nonwovens, Benson, N.C.4.4 grams of the skin cleansing composition of Example 11 is appliedevenly to the back (flat side) of a 10 inch by 8.5 inch rectangle of thefirst substrate. A second substrate which is a lofty, high wet strength,adhesive bonded cellulose paper towel with a basis weight of about 53gsm is cut to a size of about 10 inches by 8.5 inches. A useful towel isavailable from The Procter & Gamble Company and marketed as Bounty Rinse& Reuse®, which retains its Z-direction height when wet, and which has athickness of about 0.047 inches at 5 gsi, a Loft/Soft ratio of about1.28, and a high Crepe Ratio by being wet-formed on a shaped belt. Thesubstrates are heat bonded at the edge and 4 dots in the article center(5 mm diameter, spaced evenly from each other and the nearest edge)using a pressure-platen heat sealing device such as a Sentinel Model 808heat sealer available from Sencorp, Hyannis, Mass. The article istrimmed, and 3 grams of the skin conditioning composition of Example 18is applied hot by brushing onto both sides of the article. The articleis cooled and packaged until ready for use.

Example 173

[0435] Prepare a representative skin cleansing and conditioning articlein the following manner.

[0436] A first side is prepared. A first layer of the first side isprepared which is a polyester batting having a basis weight of 2 oz/yd²and is comprised of a blend of fibers of about 23 microns and 40 micronsaverage diameter, at least some of which are crimped. The thickness ofthe batting is about 0.23 in. measured at 5 gsi. The batting has an airpermeability of about 1270 cfm/ft² and a foam permeability criticalpressure of about 2.7 cm H₂O. The batting is believed to be heat-bonded,utilizing no adhesive. The batting is cut into a 10 inch square. Asecond layer of the first side is prepared which is a 10 inch squaresheet of microapertured 100 mesh formed film prepared by forminghydroapertures at high pressure on a drum comprising a 100 mesh formingscreen (e.g., as disclosed in U.S. Pat. No. 4,629,643). The sheet islaid on the first layer with the male apertured side facing up.Twenty-five grams of the skin cleansing composition of Example 1 isplaced on the center of the first side. The composition is slightlyflattened, shaped to be about ½ inch thick and several inches indiameter. A layer of an impermeable polyethylene film is placed acrossthe composition, measuring the same 10 inch square dimension as thefirst layer. Twenty-five grams of the skin conditioning composition ofExample 63 is shaped the same as the cleansing composition, and placedon top of the film in the same x-y position as the surfactant. A layerof a microapertured and macroapertured formed film which (also disclosedin U.S. Pat. No. 4,629,643) is placed with the male side of themacroapertures facing towards the composition and the male side of themicroapertures facing up. The layer is also cut to a 10 inch square. Alast layer is prepared which is a hydroentangled blend of fibers, havingsoft, fine denier fibers. The layer is prepared by airlaying two webscomprising 3 denier polyester (PET) fibers, one web on top of the other,each having a basis weight of about 17 gsm. A web of an elastomericscrim having fibers of about 100 micron diameter in one direction lacedwith fibers of about 40 micron diameter in the other direction, laced atabout 1.0 cm intervals, is fed over the fibrous webs continuously as athird web. Such a web is available from Conwed Plastics, Minneapolis,Minn. Fourth and fifth webs comprising 3 denier polyester fibers areairlaid at about 17 gsm each on top of the web. The webs arehydroentangled to fix them into a single web unit, and dried on dryingcans until moisture free. The web is creped due to web tension duringthe hydroentangling and drying process and subsequent relaxation afterprocessing. A piece of the layer is cut to a size of about 10 inches by10 inches and placed over the top of the other layers. The layers aresealed together with a pressure-platen type heat sealing device such asa Sentinel Model 808 heat sealer available from Sencorp, Hyannis, Mass.A recessed (unheated) bottom plate is used which is shaped to containthe composition and a recessed (heated) top plate which matches thebottom plate around the circular sealing rim is used to effect a heatseal. Typical sealing conditions are 300□ C. for about 3.5 seconds dwelltime with a supply pressure of about 30 psig to the machine, but willvary according to the sealing apparatus used. The article is trimmed andpackaged until ready for use.

[0437] All documents cited in the Detailed Description of the Inventionare, in relevant part, incorporated herein by reference; the citation ofany document is not to be construed as an admission that it is prior artwith respect to the present invention.

[0438] While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A substantially dry, disposable, multilayeredpersonal care article suitable for cleansing, said article comprising:a) a water insoluble substrate comprising: i) a batting layer comprisinga composite material; ii) a nonwoven layer which is disposed adjacent tosaid batting layer; and b) a cleansing component disposed adjacent tosaid water insoluble substrate, wherein said component comprises fromabout 10% to about 1000%, by weight of the water insoluble substrate, ofa lathering surfactant.
 2. The article of claim 1 wherein said battinglayer comprises fibers having a cross section thickness of from about0.5 microns to about 150 microns.
 2. The article of claim 1, whereinsaid batting layer comprises multicomponent fibers.
 3. The article ofclaim 3, wherein said multicomponent fibers are bicomponent fibers in acore sheath arrangement.
 4. The article of claim 1 wherein said battinglayer composite material is selected from the group consisting offibrous nonwovens, sponges, foams, reticulated foams, polymeric nets,scrims, vacuum-formed laminates, formed films, formed film compositematerial and combinations thereof.
 5. The article of claim 5 whereinsaid batting layer composite material is a formed film compositecomprising at least one formed film and at least one nonwoven.
 6. Thearticle of claim 1 wherein said batting layer composite materialcomprises two or more plies superimposed physically.
 7. The article ofclaim 7 wherein said two or more plies joined together continuously. 8.The article of claim 1, wherein said batting composite material has adensity between 0.00005 gm/cm³ and 0.10 gm/cm³.
 9. The article of claim1, wherein said batting composite layer has a thickness of from about0.04 to 2 inches.
 10. The article of claim 1 wherein said nonwoven layercomprises materials selected from the group consisting of cellulosicnonwovens, non-lofty nonwovens, formed films, non-lofty battings, foams,sponges, reticulated foams, vacuum-formed laminates, scrims, polymericnets, and combinations thereof.
 11. The article of claim 1, wherein saidnonwoven layer is apertured.
 12. The article of claim 12, wherein saidapertures have a diameter of from about 0.5 to about 5 mm.
 13. Thearticle of claim 1 wherein said nonwoven layer comprises a compositematerial comprising additional layers.
 14. The article of claim 14wherein said nonwoven layer composite material comprises formed films.15. The article of claim 1, wherein said batting layer and said nonwovenlayer are bonded to form a single composite layer comprising a firstside and a second side.
 16. The article of claim 16 wherein the bondingis selected from the group consisting of spot bonding, continuousjoining, in a discontinuous pattern, bonding at the external edges,bonding at discrete loci or combinations thereof.
 17. The article ofclaim 16, wherein said first side and said second side having differenttextures.
 18. The article of claim 1, further comprising one or moreadditional layers wherein said layers are attached to said batting andsaid nonwoven layers.
 19. The article of claim 19, wherein said one ormore additional layers having a thickness of at least one millimeter.20. The article of claim 1 wherein said cleansing component is disposedbetween said batting layer and said nonwoven layer of said waterinsoluble substrate.
 21. The article of claim 1 wherein said cleansingcomponent is impregnated into and/or onto said batting layer and/or saidnonwoven layer of said water insoluble substrate.
 22. The article ofclaim 1 wherein said lathering surfactant is selected from the groupconsisting of anionic lathering surfactants, cationic latheringsurfactants, nonionic lathering surfactants, amphoteric latheringsurfactants, and combinations thereof.
 23. The article of claim 23, saidlathering surfactants are selected from the group consisting of anioniclathering surfactants selected from the group consisting of ammoniumlauroyl sarcosinate, sodium trideceth sulfate, sodium lauroylsarcosinate, ammonium laureth sulfate, sodium laureth sulfate, ammoniumcocoyl isethionate, sodium cocoyl isethionate, sodium lauroylisethionate, sodium cetyl sulfate, sodium monolauryl phospate, sodiumcocoglyceryl ether sulfonate, sodium C₉-C₂₂ soap, and combinationsthereof; nonionic lathering surfactants selected from the groupconsisting of lauramine oxide, cocoamine oxide, decyl polyglucose,lauryl polyglucose, sucrose cocoate, C12-14 glucosamides, sucroselaurate, and combinations thereof; cationic lathering surfactantsselected from the group consisting of fatty amines, di-fatty quaternaryamines, tri-fatty quaternary amines, imidazolinium quaternary amines,and combinations thereof; amphoteric lathering surfactants selected fromthe group consisting of disodium lauroamphodiacetate, sodiumlauroamphoacetate, cetyl dimethyl betaine, cocoamidopropyl betaine,cocoamidopropyl hydroxy sultaine, and combinations thereof.
 24. Asubstantially dry, disposable, multilayered personal care articlesuitable for cleansing, said article comprising: c) a water insolublesubstrate comprising: i) a batting layer comprising a composite materialcomprising a nonwoven layer; and d) a cleansing component disposedadjacent to said water insoluble substrate, wherein said componentcomprises from about 10% to about 1000%, by weight of the waterinsoluble substrate, of a lathering surfactant.
 25. A method ofcleansing the skin and hair which comprise the steps of: a) wetting thearticle of claim 1; and b) contacting the skin or hair with the wettedarticle.
 27. A substantially dry, disposable personal care articlesuitable for conditioning, said article comprising: a) a water insolublesubstrate comprising: 1) a batting layer comprising a compositematerial; and 2) a nonwoven layer which is disposed adjacent to saidbatting layer; and b)a therapeutic benefit component, disposed adjacentto said water insoluble substrate, wherein said component comprises fromabout 10% to about 1000%, by weight of the water insoluble substrate, ofa therapeutic benefit agent.
 28. The article of claim 27 wherein thetherapeutic benefit agent is selected from the group consisting ofhydrophobic conditioning agents, hydrophilic conditioning agents,structured conditioning agents, and combinations thereof.
 29. Thearticle of claim 28 wherein said therapeutic benefit agent is in theform of an emulsion.
 30. The article of claim 29 wherein said emulsionis a water-in-oil emulsions.
 31. The article of claim 27 wherein saidtherapeutic benefit agent is in the form of a coacervate-formingcomposition.
 32. A method of conditioning the skin and hair whichcomprise the steps of: a) wetting the article of claim 27; and b)contacting the skin or hair with the wetted article.
 33. A substantiallydry, disposable personal care article suitable for both cleansing andconditioning, said article comprising: a) a water insoluble substratecomprising: 1) a batting layer comprising a composite material; and 2) anonwoven layer which is disposed adjacent to said batting layer; b) acleansing component disposed adjacent to said batting layer, whereinsaid component comprises from about 10% to about 1000%, by weight of thewater insoluble substrate, of a lathering surfactant; and c) atherapeutic benefit component, disposed adjacent to said water insolublesubstrate, wherein said component comprises from about 10% to about1000%, by weight of the water insoluble substrate, of a therapeuticbenefit agent.
 34. A method of cleansing and condition skin and hair,said method comprising the steps of: a) wetting the article of claim 33;b) contacting the skin or hair with the wetted article.
 35. A personalcare kit comprising the article of claim 1 and an additional articlewhich comprises a substrate and a therapeutic benefit component.
 36. Apersonal care kit comprising the article of claim 27 and an additionalarticle which comprises a substrate.